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CHAPTER 1


                                INTRODUCTION


1.1    INTRODUCTION TO THE STUDY
           Safety is inevitable to any organization when employees are involved. An
organization’s responsibility to its employees extends beyond the payment of wages for
their services. The employee’s safety both on and off the job within the organization is a
vital concern of the employer. Providing a safe and healthy environment is a pre-
requisite for any productive effort. This research deals with the study on the safety
provided to the employees at Caterpillar.


Introduction to Safety- Begin this course with an overview of effective safety and health
programs and an understanding of their importance to both employers and employees.
Discover methods for implementing safety programs in the industrial workplace.


Walking and working Surfaces- Identify common hazards that may increase the
probability of workplace accidents. Study proper “House Keeping” and the correct use
of ladders and stairways. Identify when to use covers and guardrails and the steps that
can be taken to minimizing slipping, tripping, and falling in the workplace.


Prevention and Protection Plans- Study the importance of an effective emergency
management plan in reducing workplace injuries and deaths. Learn that an effective
safety plan includes proper and clearly marked exits, functioning and regularly
maintained fire-fighting equipment and employee training programs.




Employee Safety:
                                            1
A top priority for any employer should be to take the time and initiative to
help protect their employees. If an employee becomes injured at work, your business
may suffer.
              Machines in the workplace can pose operating hazards. From minor cuts and
abrasion to serious lacerations, exposure to machine operations can be detrimental to
life, health and productivity. It is highly recommended that you purchase machinery
equipped with guarding or that the guards on existing equipment left intake and
employees be trained to use them.


Hazards Materials
              Chemicals and solvents in the workplace can create hazardous conditions.
Some combinations of common cleaning chemicals can cause serious life threatening
conditions.
                 •   Use a designated storage place for chemicals
                 •   Read the labels on your products and become familiar with material
                     safety data sheets.


Personal Protective Equipment (PPE)
              When the workplace hazards cannot be eliminated or reduced, personal
protective equipment may be necessary. PPE does not eliminate a hazardous situation; it
simply creates a protective barrier between the employee and the hazard. Equipment
can be in the form of;


Non respirators
                  Safety glasses or goggles
                  Gloves
                  Boots
                  Hearing protection
                  Hardhats
                  Helmet
                  Earplug
                  Apron
                                               2
 Leg guard
                Arm shield
                Wind shield


Respirators
            Dust respirators
            Chemical respirators
            Welding fume
            Visual air system


Definitions of safety
       System Safety Engineering and Management states that safety may be defined
“as a quality of a system that allows the system to function under pre-determined
conditions with an acceptable minimum of accidental loss”.


       Air services Australia (2001, AA-Safe-001, p.1) define safety as “Being in a
situation where the risks of an aircraft accident or air safety incident are reduced to a
level as a low as reasonable practicable” reinforcing the proposition that the working
definition of Safety includes risk management.


       Safety can be framed for the purposes of this paper as a characteristic of a system
that does not permit unacceptable risks to be undertaken with the goal of injury free
operations.
        The condition of being safe; freedom from danger, risk, or injury.
        the state of being certain that adverse effects will not be caused by some agent
          under defined conditions
        Occupational safety is concerned with risks in areas where people work:
          offices, manufacturing plants, farms, construction sites, and commercial and
          retail facilities. Public safety is concerned with hazards in the home, in travel
          and recreation, and in other situations that do not fall within the scope of
          occupational safety.

              1.2 NEED AND IMPORTANCE OFTHE STUDY
                                            3
1. This study would give an overview of the safety measures existing at
     Caterpillar.
2. Since safety and welfare are two important elements essential for improving the
     productivity of an organization, a study on the existing safety measures would
     help the organization perform better.
3.    This study would throw light on the perception of the employees regarding
     safety.
4. Caterpillar can identify the areas where it can improve so as to improve the
     performance of the employees.
5. This study would also help to analyze if there is dependence between
     departments and categories and the level of satisfaction of safety measures
6. Suggest provisions of more safety measures.




                                         4
1.3 SCOPE OF THE STUDY



       The study undertaken for CATERPILLAR aims to find the reason for safety
measures. This study is done with the help of a questionnaire which contains questions
which probe into the details so as to find the reason of their choice.


           Safety and welfare are two important elements essential for improving the
productivity of an organization, a study on the existing safety measures would help the
organization perform better.


       Safety measures may be viewed as a total concept and as a relative concept. The
total concept is a desirable state of existence involving the physical, mental, moral and
economical well-being. These four elements together constitute the structure of the
welfare implies the welfare of man, his family and community.




                                             5
1.4 OBJECTIVES OF THE STUDY


Primary Objectives:
       A study on “The Effectiveness of Safety Management System” in Caterpillar
India Private Ltd.


Secondary Objectives:
            To find out whether adequate safety measures are provided to the
               employees
            To find out the fulfillment of safety measures to employees
            To analyze the safety measures followed by the contract laborers
            To observe the employees satisfaction towards the safely training
               program
            To find out the employees expectation towards safety measures in this
               company.




                                          6
1.5 LIMITATIONS OF THE STUDY


 The study is applicable to “CATERPILLAR PVT LIMITED”
 The respondents have replied to the queries recalling from their memory.
  Therefore recall bias and personal bias are possible.
 The sample size was limited to 100.
 Since the data was collected using a schedule, the interviewer’s inability to
  understand and record the responses correctly is possible.
 The respondents were unable or unwilling to give a complete and accurate
  response to certain questions.




                                    7
1.6 COMPANY PROFILE
        For more than 80 years, Caterpillar has been building the world’s infrastructure
and, in partnership with network of Cat® dealers worldwide, has helped drive positive
and sustainable change on every continent. They are a global company, with hundreds
of locations worldwide to serve and support customer base, and respond quickly to their
needs
        .
Corporate Profile
        For more than 80 years, Caterpillar Inc. has been making progress possible and
driving positive and sustainable change on every continent. With 2008 sales and
revenues of $51.324 billion, Caterpillar is the world’s leading manufacturer of
construction and mining equipment, diesel and natural gas engines and industrial gas
turbines. The company also is a leading services provider through Cat Financial
Services, Cat Remanufacturing Services, Cat Logistics Services and Progress Rail
Services. They are proud to be a leader in building the world’s infrastructure, and in
enabling progress for millions of people around the globe. They manufacture more than
300 products in 23 countries and serve customers in nearly 200 countries. They are
headquartered in Peoria, Illinois.


The History of Caterpillar


1890. Benjamin Holt and Daniel Best experimented with various forms of steam tractors
for use in farming. They did so separately, with separate companies.


1904. Holt's first steam track-type tractor.


1906. Holt's first gas track-type tractor.


1915. Holt "Caterpillar®" track-type tractors are used by the Allies in World War I.


1925. The Holt Manufacturing Company and the C. L. Best Tractor Co. merge to form
Caterpillar Tractor Co.



                                               8
1931. The first Diesel Sixty Tractor rolled off the assembly line in East Peoria, Illinois,
with a new efficient source of power for track-type tractors.


1940. The Caterpillar product line now included motor graders, blade graders, elevating
graders,           terracers          and           electrical       generating             sets.


1942. Caterpillar track-type tractors, motor graders, generators sets and a special engine
for     the   M4    tank    are     used    by     the   United   States   in   its     war    effort.


1950. Caterpillar Tractor Co. Ltd. in Great Britain is established, the first of many
overseas operations created to help manage foreign exchange shortages, tariffs, import
controls       and         better      serve         customers      around            the      world.


1953. In 1931, the company created a separate engine sales group to market diesel
engines to other equipment manufacturers. This group was replaced in 1953 with a
separate sales and marketing division to better serve the needs of a broad range of
engine customers. Engine sales now account for approximately one-third of the
company's                  total                 sales            and                 revenues.


1963. Caterpillar and Mitsubishi Heavy Industries Ltd. form one of the first joint
ventures in Japan to include partial U.S. ownership. Caterpillar Mitsubishi Ltd. started
production in 1965, has been renamed Shin Caterpillar Mitsubishi Ltd., and is now the
No. 2 maker of construction and mining equipment in Japan.


1981-83. the worldwide recession took its toll on Caterpillar, costing the company the
equivalent of $1 million a day and forcing it to dramatically reduce employment.


1983. Caterpillar Leasing Company is expanded to offer equipment financing options to
its customers worldwide and is renamed Caterpillar Financial Services Corporation.


1985-present. The product line continued to diversify to meet a variety of customer
needs. More than 300 products are now offered, more than double the figure in
1981.

                                                    9
1986. The Caterpillar Tractor Co. changes its name to Caterpillar Inc. - a more accurate
reflection of the enterprise's growing diversity.


1987. A $1.8 billion plant modernization program was launched to streamline the
manufacturing process.


1990. The company decentralized its structure, reorganizing into business units
responsible for return on assets and customer satisfaction.


1997. The company continued to expand, acquiring the U.K.-based Perkins Engines.
With the addition of Germany's MaK Motoren the previous year, Caterpillar becomes
the world leader in diesel engine manufacturing.


1998. The world's largest off-highway truck - the 797 - makes its debut at the Cat Proving
Ground in Arizona.


1999. Caterpillar unveils new line of compact construction equipment at CONEXPO,
world's largest construction show, in response to changing customer needs for smaller,
more versatile construction equipment.


2000. Caterpillar celebrates its 75th anniversary.


2001. Caterpillar is the first company to globally launch 6 Sigma and deliver first-year
benefits in excess of implementation costs.


2003. Caterpillar becomes the first engine manufacturer to offer a complete line of 2004
model year clean diesel engines fully compliant and certified by the U.S. Environmental
Protection Agency (EPA). Caterpillar's breakthrough emissions control technology,
known as ACERT®, is designed to comply with EPA standards without sacrificing
performance, reliability or fuel efficiency.


2005. Demonstrating a pledge to sustainable development, Caterpillar responded to a
number of tragedies around the world, including the Asian Tsunami disaster, hurricanes


                                               10
along the U.S. Gulf Coast and earthquakes in South Asia. In the face of each of these
challenges, employees, dealers and corporate leaders alike joined together to build a
promise of hope and growth for all those affected by donating machinery, money and
resources for relief and recovery efforts.


2006. Benjamin Holt, one of Caterpillar Inc.'s founding fathers and designer of the first
track-type tractor was recognized for his ingenuity and entrepreneurial spirit with an
induction into the National Inventors Hall of Fame.


2006. Caterpillar Inc. subsidiary Caterpillar Logistics Services, Inc. (Cat Logistics) opens
a new parts distribution center in the Lingang Industrial Area in Shanghai.


2006. Caterpillar launched a revised and updated Worldwide Code of Conduct and
Enterprise Strategy. Serving new markets and new customers in new ways, Caterpillar
welcomed the opportunity to experience unchartered growth across all business
ventures.




Mission
          Their mission is to enable economic growth through infrastructure
And energy development, and provide solutions that protect people and preserve the
planet.

Vision
          Their vision is a world in which all people’s basic requirements—such as
Shelter, clean water, sanitation and reliable power—are fulfilled in a way that sustains
our environment.

Strategy
          Their strategy is to provide work environments, products, services and solutions
that make efficient use of the world’s natural resources and reduce unnecessary impacts
on people, the environment and the economy. This means that they leverage resources,
including technology and innovation to:



                                             11
•   Optimize the use of renewable resources
   •   Minimize emissions
   •   Maximize recycling
   •   Promote and protect individual Safety and well-being
   •   Minimize the use of energy, materials, water and land
   •   Provide employment, education and training




Sustainable Development Critical Success Factors (CSFs) Progress
Culture
       Create a culture of sustainable development in all their business units and in all
their daily work.
Operations
       Be consistent with their sustainability principles and contribute to enterprise
sustainable development goals.
Business Opportunities
       Identify and pursue business growth opportunities created by sustainable
development.


Caterpillar Enterprise Goals to 2020 (Baseline 2006)
       Established in 2007, these aspirational, enterprise-wide goals focus on
sustainability in every aspect of their business.
2020 Goals for
Products, Services and Solutions
   •   Reduce customer greenhouse gas emissions by 20%
   •   Increase customer energy efficiency by 20%
   •   Provide leadership in the safety of people in, on and around our products
   •   Increase customer material efficiency by 20%




                                             12
2020 Goals for
Operations
   •   Use alternative/renewable sources to meet 20% of their energy needs
   •   Reduce recordable workplace injury rates to 0.6 and lost-time case rate due to
       injury to 0.15
   •   Increase energy efficiency by 25%
   •   Design all new construction to meet Leadership in Energy and Environmental
       Design(LEED) or comparable green building criteria
   •   Eliminate waste by reducing Hold water consumption flat waste generation and
       reusing or recycling all that remains
   •   Reduce absolute greenhouse gas emissions from existing facilities by 25%




                                           13
1.7 Industry Profile


       Indian Infrastructure sector is currently going through a vast transformation
with the third largest road network of 3 million Km crisscross the country, the
automobile revolution has more than doubled from 21.3 million at the beginning of
1990’s to 48.4 million by end of the decade.


       The Government has already embarked upon massive road construction projects,
with national highway development from building the North-South and East-West
corridors and golden quadrangle projects connecting major cities. Besides government’s
decision to throw open the construction of roads, bridges and airports to private sector
and allowing 100% foreign investment in real estate projects, has provided a boost to the
construction industry as well as generate demand for construction machinery.


       The total investment of road and highway construction project is estimated as
$40 billion turnover the next 15 years of which 20% is expected to be in construction
machinery. Hence a total demand of $10 billion construction machinery is expected in
next 20 years.


       The present market for construction machinery is estimated to $1312.17 million,
out of which about 1% is imported. Indian construction machinery Industry is
undergoing a rapid transformation from low volume, intensive use of equipment
structure to high volume, and specific use one. The new housing and infrastructure
ventures have generated substantial demand for construction machinery, manufacturing
and servicing. While the previous trend was to forge joint venture associations with
Indian companies, more and more multinational companies are now entering the Indian
market on their own strength.


The major manufacturers and importers of the estimated $1312.17 industry are:


            Ashok Leyland
            Atlas Copco (India)
                                               14
 B G Shirke Construction Equipment
            Caterpillar India
            Ingersoll Rand India
            JCB India
            Larsen & Toubro
            Metso Minerals
            Salgaocar Engineers
            Schwing-Stetter India
            Telco Construction Equipment
            Terex Vectra Equipment
            Voltas


In India, Caterpillar languishes in fourth position in sales of diggers, loaders and other
construction machines.

The key Success Factors are:

Focus on quality and operational efficiency
       From the outset, CIPL has had a strong focus on quality. To this end, it focused
on implementing Six Sigma and the pursuit of operational excellence using Class A
disciplines.
Superior product development capabilities
       Caterpillar’s unique New Product Introduction (NPI) process gives guidance,
direction and accountability to all stakeholders while ensuring its overall success. The
cornerstone of this product development process is the customer validation exercise
where machines are placed in a non-clinical environment and evaluated for more than
3,500 hours. The company uses tools like the Prediction of Estimated Reliability Growth
Plan (PERG) and Statistical tools such as the Weibull Analysis for checking machine
performance prior to launch. Such processes and tools enabled the company to
successfully launch the backhoe loader, and assure success in a competitive market.
World Wide Competitors of Caterpillar are:
            Komatsu(Japan)

            Hitachi(Japan)
                                            15
 CNH-Case new Holland(France)

 John Deer(USA)

 Volvo (Sweden).




                          16
1.8 REVIEW OF LITERATURE


Definitions of safety


        The condition of being safe; freedom from danger, risk, or injury.
        the state of being certain that adverse effects will not be caused by some agent
          under defined conditions
        Occupational safety is concerned with risks in areas where people work:
          offices, manufacturing plants, farms, construction sites, and commercial and
          retail facilities. Public safety is concerned with hazards in the home, in travel
          and recreation, and in other situations that do not fall within the scope of
          occupational safety.




Introduction


Introduction to safety- Being this course with an overview of effective safety and health
programs and an understanding of their importance to both employers and
employees .Discover methods for implementing safety programs in the industrial
workplace.


Employee safety:
      A top priority for any employer should be to take the time and initiative to help
protect their employees becomes at work, your business may suffer.
        Machines in the work place can pose operating hazards. From minor cuts and
abrasion to serious lacerations, exposure to machine operations can be detrimental to
life, health and productivity. It is highly recommended that you purchased machinery
equipped with guarding or that the guards on existing equipment left intake and
employees be trained to use them.


                                           17
FACTORIES ACT, 1948


            The Factories Act is a social legislation which has been enacted for
occupational safety, health and welfare of workers at work places. This legislation is
being enforced by technical officers i.e. Inspectors of Factories, Dy. Chief Inspectors of
Factories who work under the control of the Chief Inspector of Factories and overall
control of the Labour Commissioner, Government of National Capital Territory of Delhi


SALIENT FEATURES OF THE ACT ARE:-

1. Approval of Factory Building Plans before construction/extension, under the Delhi
    Factories Rules, 1950.
2. Grant of Licenses under the Delhi Factories Rules, 1950, and to take action against
    factories running without obtaining License.
3. Renewal of Licenses granted under the Delhi Factories Rules, 1950, by the Dy. Chief
    Inspectors of Factories.
4. Inspections of factories by District Inspectors of Factories, for investigation of
    complaints, serious/fatal accidents as well as suo moto inspections to check
    compliance of provisions of this Act relating to :-




                                             18
I.
He
alt
h


II.
Saf
ety


III
    .
W
elf
are
fac
ilit
ies


IV.
W
or
ki
ng
ho
ur
s


V.
E
m
pl
oy
me
nt      19
1.CLEANLINESS:Every factory shall be kept clean and free from effluvia arising from
any drain, privy or other, nuisance, and in particular - (a) accumulations of dirt and
refuse shall be removed daily by sweeping or by any other effective method from the
floors and benches of workrooms and from staircases and passages, and disposed of in a
suitable manner;


(b) The floor of every workroom shall be cleaned at least once in every week by
washing, using disinfectant, where necessary, or by some other effective method;


(c) where a floor is liable to become wet in the course of any manufacturing process to
such extent as is capable of being drained, effective means of drainage shall be provided
and maintained;


(d) all inside walls and partitions, all ceilings or tops of rooms and all walls, sides and
tops of passages and staircases shall - (ii) where they are painted otherwise than with
washable water-paint or varnished, be repainted or re-varnished least once in every
period of five years;


(ii) Where they are painted or varnished or where they have smooth impervious
surfaces, be cleaned at least once in every period of fourteen months by such method as
may be prescribed;


(iii) In any other case, be kept whitewashed or color-washed, and the whitewashing or
color-washing shall be carried out at least once in every period of fourteen months;


(d) All doors and window frames and other wooden or metallic frame work and
shutters shall be kept painted or varnished and the painting or varnishing shall be
carried out at least once in every period of five years;


(e) The dates on which the processes required by clause (d) are carried out shall be
entered in the prescribed register.


(2) If, in view of the nature of the operations carried on in a factory or class or
description of factories or any part of a factory or class or description of factories, it is

                                              20
not possible for the occupier to comply with all or any of the provisions of sub-section
(1), the State Government may by order exempt such factory or class or description of
factories or part from any of the provisions of that sub-section and specify alternative
methods for keeping the factory in a clean state.


12. DISPOSAL OF WASTES AND EFFLUENTS. - (1) Effective arrangements shall be
made in every factory for the treatment of wastes and effluents due to the
manufacturing process carried on therein, so as to render them innocuous, and for their
disposal.


(2) The State Government may make rules prescribing the arrangements to be made
under sub-section (1) or requiring that the arrangements made in accordance with sub-
section (1) shall be approved by such authority as may be prescribed.




13. VENTILATION AND TEMPERATURE. - (1) Effective and suitable provision shall
be made in every factory for securing and maintaining in every workroom - (a) adequate
ventilation by the circulation of fresh air, and


(b) Such a temperature as will secure to workers therein reasonable conditions of
comfort and prevent injury to health; and in particular, - (i) walls and roofs shall be of
such material and so designed that such temperature shall not be exceeded but kept as
low as practicable;


(ii) Where the nature of the work carried on in the factory involves, or is likely to
involve, the production of excessively high temperatures such adequate measures as are
practicable shall be taken to protect the workers there from, by separating the process
which produces such temperatures from the workroom, by insulating the hot parts or by
other effective means.


(2) The State Government may prescribe a standard of adequate ventilation and
reasonable temperature for any factory or class or description of factories or parts
thereof and direct that [ lra-48 proper measuring instruments, at such places and in such
                                             21
position as may be specified, shall be provided and such records, as may be prescribed,
shall be maintained;


(3) If it appears to the Chief Inspector that excessively high temperatures in any factory
can be reduced by the adoption of suitable measures, he may, without prejudice to the
rules made under sub-section (2), serve on the occupier, an order in writing specifying
the measures which, in his opinion, should be adopted, and requiring them to be carried
out before a specified date.


14. DUST AND FUME. - (1) In every factory in which, by reason of the manufacturing
process carried on, there is given off any dust or fume or other impurity of such a nature
and to such an extent as is likely to be injurious or offensive to the workers employed
therein, or any dust in substantial quantities, effective measures shall be taken to
prevent its inhalation and accumulation in any workroom, and if any exhaust appliance
is necessary for this purpose, it shall be applied as near as possible to the point of origin
of the dust, fume or other impurity, and such point shall be enclosed so far as possible.


(2) In any factory no stationary internal combustion engine shall be operated unless the
exhaust is conducted into the open air, and no other internal combustion engine shall be
operated in any room unless effective measures have been taken to prevent such
accumulation of fumes therefore as are likely to be injurious to workers employed in the
room.


15. ARTIFICIAL HUMIDIFICATION. - (1) In respect of all factories in which the
humidity of the air is artificially increased, the State Government may make rules, - (a)
prescribing standards of humidification;


(b) Regulating the methods used for artificially increasing the humidity of the air,


(c) Directing prescribed tests for determining the humidity of the air to be correctly
carried out and recorded;


(d) Prescribing methods to be adopted for securing adequate ventilation and cooling of
the air in the workrooms.
                                             22
(2) In any factory in which the humidity of the air is artificially increased, the water used
 for the purpose shall be taken from a public supply, or other source of drinking water, or
 shall be effectively purified before it is so used.


 (3) If it appears to an Inspector that the water used in a factory for increasing humidity
 which is required to be effectively purified under sub-section (2) is not effectively
 purified he may serve on the manager of the factory an order in writing, specifying the
 measures which in his opinion should be adopted, and requiring them to be carried out
 before specified date.


 16. OVERCROWDING. - (1) No room in any factory shall be overcrowded to an extent
 injurious to the health of the workers employed therein.


   (2) Without prejudice to the generality of sub-section (1), there shall be in every
 workroom of a factory in existence on the date of the commencement of this Act
 at least 9.9 cubic meters and of a factory built after the commencement of this Act
 at least 14.2 cubic meters or space for every worker employed therein, and for the
 purposes of this sub-section no account shall be taken of any space which is more
 than 4.2 meters above the level of the floor of the room.


 (3) If the Chief Inspector by order in writing so requires, there shall be posted in each
 workroom of a factory a notice specifying the maximum number of workers who may,
 in compliance with the provisions of this section, be employed in the room.


 (4) The Chief Inspector may by order in writing exempt, subject to such conditions, if
any, as he may think fit to impose, any workroom from the provisions of this section, if he
is satisfied that compliance therewith in respect of the room is unnecessary in the interest
of the health of the workers employed therein.


 17. LIGHTING. (1) In every part of a factory where workers are working or passing
 there shall be provided and maintained sufficient and suitable lighting, natural or
 artificial, or both.




                                               23
(2) In every factory all glazed windows and skylights used for the lighting of the
workroom shall be kept clean on both the inner and outer surfaces and, so far as
compliance with the provisions of any rules made, under sub-section (3) of section 13
will allow, free from obstruction.


(3) In every factory effective provision shall, so far as is practicable, be made for the
prevention of - (a) glare, either directly from a source of light or by reflection from a
smooth or polished surface;


(b) The formation of shadows to such an extent as to cause eye-strain or the risk of
accident to any worker.


(4) The State Government may prescribe standards of sufficient and suitable lighting for
factories or for any class or description of factories or for any manufacturing process.


18. DRINKING WATER. - (1) In every factory effective arrangements shall be made to
provide and maintain at suitable points conveniently situated for all workers employed
therein a sufficient supply of wholesome drinking water.


(2) All such points shall be legibly marked "drinking water" in a language understood by
a majority of the workers employed in the factory, and no such point shall be situated
within six meters of any washing place, urinal, latrine, spittoon, open drain carrying
salvage or effluent or any other source of contamination unless a shorter distance is
approved in writing by the Chief Inspector.


(3) In every factory wherein more than two hundred and fifty workers are ordinarily
employed, provisions shall be made for cooling drinking water during hot weather by
effective means and for distribution thereof.


(4) In respect of all factories or any class or description of factories the State Government
may make rules for securing compliance with the provisions of sub-sections (1), (2) and
(3) and for the examination by prescribed authorities of the supply and distribution of
drinking water in factories.


                                              24
19. LATRINES AND URINALS. - (1) In every factory - (a) sufficient latrine and urinal
accommodation of prescribed types shall be provided conveniently situated and
accessible to workers at all times while they are at the factory;


(b) Separate enclosed accommodation shall be provided for male and female workers;


(c) Such accommodation shall be adequately lighted and ventilated, and no latrine or
urinal shall, unless specially exempted in writing by the Chief Inspector, communicate
with any workroom except through an intervening open space or ventilated passage;


(d) All such accommodation shall be maintained in a clean and sanitary condition at all
times;


(e) Sweepers shall be employed whose primary duty it would be to keep clean latrines,
urinals and washing places.


(2) In every factory wherein more than two hundred and fifty workers are ordinarily
employed - (a) all latrine and urinal accommodation shall be of prescribed sanitary
types;


(b) the floors and internal walls, up to a height of ninety centimeters, of the latrines and
urinals and the sanitary blocks shall be laid in glazed titles or otherwise finished to
provide a smooth polished impervious surface;


(c) without prejudice to the provisions of clauses (d) and (e) of sub-section (1), the floors,
portions of the walls and blocks so laid or finished and the sanitary pans of latrines and
urinals shall be thoroughly washed and cleaned at least once in every seven days with
suitable detergents or disinfectants or with both.


(3) The State Government may prescribe the number of latrines and urinals to be
provided in any factory in proportion to the numbers of male and female workers
ordinarily employed therein, and provide for such further matters in respect of
sanitation in factories, including the obligation of workers in this regard, as it considers
necessary in the interest of the health of the workers employed therein.

                                             25
20. SPITTOONS. –


(1) In every factory there shall be provided a sufficient number of spittoons in
convenient places and they shall be maintained in a clean and hygienic condition.


(2) The State Government may make rules prescribing the type and the number of
spittoons to be provided and their location in any factory and provide for such further
matters relating to their maintenance in a clean and hygienic condition.


(3) No person shall spit within the premises of a factory except in the spittoons provided
for the purpose and a notice containing this provision and the penalty for its violation
shall be prominently displayed at suitable places in the premises.


(4) Whoever spits in contravention of sub-section (3) shall be punishable with fine not
exceeding five rupees.


Safety Culture

An organization with a "safety culture" is one that gives appropriate priority to safety
and realizes that safety has to be managed like other areas of the business. For the
shipping industry, it is in the professionalism of seafarers that the safety culture must take
root.


That culture is more than merely avoiding accidents or even reducing the number of
accidents, although these are likely to be the most apparent measures of success. In
terms of shipboard operations, it is to do the right thing at the right time in response to
normal and emergency situations. The quality and effectiveness of that training will
play a significant part in determining the attitude and performance - the professionalism
- the seafarer will subsequently demonstrate in his, or her, work. And the attitude
adopted will, in turn, be shaped to a large degree by the 'culture' of the shipping
company.




                                             26
The key to achieving that safety culture is in:


    •   recognizing that accidents are preventable through following correct procedures
        and established best practice;
    •   constantly thinking safety; and
    •   Seeking continuous improvement.


It is relatively unusual for new types of accidents to occur on board and many of those
that continue to occur are due to unsafe acts by seafarers. These errors, or more often
violations of good practice or established rules, can be readily avoided. Those who
make them are often well aware of the errors of their ways. They may have taken short-
cuts they should not have taken. Most will have received training aimed at preventing
them but, through a culture that is tolerant to the 'calculated risk', they still occur.


The challenge for trainers and training, and managers ashore and afloat, is how to
minimize these unsafe acts, how to instill not only the skills but also the attitudes
necessary to ensure safety objectives are met. The aim should be to inspire seafarers
towards firm and effective self-regulation and to encourage personal ownership
of established best practice. Internationally recognized safety principles and the
safeguards of best industry practice have to become an integral part of an individual'
own standards.




Hazards, risks, outcomes


The terminology used in OSH varies between states, but generally speaking:


    •   A hazard is something that can cause harm if not controlled.
    •   The outcome is the harm that results from an uncontrolled hazard.
    •   A risk is a combination of the probability that a particular outcome will occur
        and the severity of the harm involved.




                                              27
“Hazard”, “risk”, and “outcome” are used in other fields to describe e.g. environmental
damage, or damage to equipment. However, in the context of OSH, “harm” generally
describes the direct or indirect degradation, temporary or permanent, of the physical,
mental, or social well-being of workers. For example, repetitively carrying out manual
handling of heavy objects is a hazard. The outcome could be a musculoskeletal disorder
(MSD) or an acute back or joint injury. The risk can be expressed numerically (e.g. a 0.5
or 50/50 chance of the outcome occurring during a year), in relative terms (e.g.
"high/medium/low"), or with a multi-dimensional classification scheme (e.g. situation-
specific risks).


Hazard Assessment

Hazard analysis or hazard assessment is a process in which individual hazards of the
workplace are identified, assessed and controlled/eliminated as close to source (location
of the hazard) as reasonable and possible. As technology, resources, social expectation or
regulatory requirements change, hazard analysis focuses controls more closely toward
the source of the hazard. Thus hazard control is a dynamic program of prevention.
Hazard-based programs also have the advantage of not assigning or implying there are
"acceptable risks" in the workplace. A hazard-based program may not be able to
eliminate all risks, but neither does it accept "satisfactory" -- but still risky—outcomes.
And as those who calculate and manage the risk are usually managers while those
exposed to the risks are a different group, workers, a hazard-based approach can by-
pass conflict inherent in a risk-based approach.


Risk assessment

        Modern occupational safety and health legislation usually demands that a risk
assessment be carried out prior to making an intervention. It should be kept in mind that
risk management requires risk to be managed to a level which is as low as is reasonably
practical.




                                             28
This assessment should:


   •   Identify the hazards
   •   Identify all affected by the hazard and how
   •   Evaluate the risk
   •   Identify and prioritize appropriate control measures


The calculation of risk is based on the likelihood or probability of the harm being
realized and the severity of the consequences. This can be expressed mathematically as a
quantitative assessment (by assigning low, medium and high likelihood and severity
with integers and multiplying them to obtain a risk factor, or qualitatively as a
description of the circumstances by which the harm could arise.


The assessment should be recorded and reviewed periodically and whenever there is a
significant change to work practices. The assessment should include practical
recommendations to control the risk. Once recommended controls are implemented, the
risk should be re-calculated to determine of it has been lowered to an acceptable level.
Generally speaking, newly introduced controls should lower risk by one level, i.e, from
high to medium or from medium to low.




                      1.9 RESEARCH METHODOLOGY
       Methodology is a systematic way to solve the research problem. It may be
understand as a science of studying how research is done logically. The various steps
that are generally adopted by a researcher problem are also the main function of the
research methodology.


RESEARCH DESIGN
               Descriptive research studies are concerned with describing the
characteristics of a particular individual or of a group, or a situation. This type of


                                            29
research design can be used in conditions where decision problem are linked to answer
specific question concerning who, what when, and how a topic. In the study the
researcher wants to elevate “how” effective the performance appraisal system are using
a structured Questionnaire for collection of data, hence the research design used is
descriptive in nature.


DATA COLLECTION
       The two types of data used for the purpose and study are Primary data &
Secondary data,


1. Primary data
        It relates to the study was collected from the operators level in the company. It
was collected through interview and questionnaire method. The other methods such as
observation, indirect oral interview and detailed discussion with the employees had
been conducted for the purpose of data collection.


2. Secondary data
       Secondary data are those which have already been collected by some other
agency and which have already been processed. Secondary data for the study has been
complied from the reports and official publication of the organization, which have
helped in getting and insight of the present scenario existing in the operation of the
company.


Sampling plan
       Sampling is the selection of some part of an aggregate or totality on the basic of
which a judgment or inference about the aggregate or totality is made.


Sampling technique
               A population is the collection of elements about which one has to make
some inference. The population was 100 the researcher followed censes sampling
method, which is the count of all elements, in a population.


                                           30
RESEARCH METHODOLOGY



Key issue                                 Options selected


Data source                               Primary and secondary data


Research approach instrument              Interview survey questionnaire


Contact method                            Personal contact.




QUESTIONNAIRE DESIGN


       The questionnaire used for collecting the data is a structured one. It was a
mixture of open ended, closed ended and multiple industry choices. The words used
were simple and help in avoiding confusion and misunderstanding among the
respondents.
       During questions were avoided in order to make sure that the questions were
arranged in a logical order and So that the respondent would not find the questions
confusing.




Sampling Procedure


               KEY ISSUES                       OPTION SELECTED


               Sample Unit
                                                         Operators

               Sample Size
                                                         100



                                        31
SAMPLING PROCEDURE
                 The first step of research design is used to formulate the objective of
research plan, which while specify the way of achieving research objectives
questionnaires were used to collect the needed information. The sampling method was
conveniences sampling and it is made in such a view freely with hesitation.


SAMPLING UNIT
                    •   The operators were surveyed
SAMPLE SIZE
                    •   100 samples of operators considered for the study.


SURVEY METHOD
       The survey method used by the researcher was self- administered survey. Self –
administered survey is data collection technique in which the respondent read the
survey question and records his /her answer without the presence of a trained
interviewer.


STATISTICAL TOOLS
1. Simple Percentage
       Percentage refers to a special kind of ration .Percentage are used in making
comparisons between two or more series of data. Percentage is used to describe
relationships.
       Percentage can also be used to compare the relative terms the distribution of two
or more or more series of data.


2. Chi-Square Analysis
       Chi square test is a non-parametric test. Marking researches to test hypotheses
uses it most frequently. The test is employed for testing hypotheses when distribution if
population is not know and when nominal data in to be analyzed.
       The quantity x2 describes the magnitude of discrepancy between theory and
observation. Verity the distribution of observed data with answered theoretical
                                            32
distribution non parametric test. The symbol “X2” is the Greek letter Chi. the Test was
first used by Kara person in the year 1990.


    The Quantity χ2 is defined as χ2          = (Oi-Ei/Ei) 2
               Where,
                        Oi = Refers to the observed frequency
                        Ei = Refers to expected frequency




                                              33
CHAPTER II

            2.1     DATA ANALYSIS AND INTERPRETATION

                            1.1.1 PERCENTAGE ANALYSIS

TABLE: 2.1.1          DISTRIBUTION OF THE RESPONDENTS-
                      AGE WISE

                                                No. of
          S. No        Particulars           respondents           Percentage
             1     Up to 20                        0                    0
             2     21-30                          10                   10
             3     31-40                          20                   20
             4     41-50                          50                   50
             5     Above50                        20                   20
                         Total                   100                  100

CHART: 2.1.1          DISTRIBUTION OF THE RESPONDENTS-
                      AGE WISE




INFERENCE:
       It is found from the above table that 10% of the respondents between 21-30 years
of age level, 20% of the respondents between 31-40 years of age level, 50% of the
respondents between 41-40 years of age level, 20% of the respondents belongs to above
50 years of age level and none of the respondents are below 20 years of age,

                                           34
TABLE: 2.1.2         DISTRIBUTION OF THE RESPONDENTS-
                     DESIGNATION WISE

                                                  No. of
            S. No           Particulars        Respondents      Percentage
               1      Operator                     65               65
               2      Fitter                       15               15
               3      Welder                       10               10
               4      Burner                        4                4
               5      Painter                       6                6
                      Total                        100              100

CHART: 2.1.2         DISTRIBUTION OF THE RESPONDENTS-
                     DESIGNATION WISE




INFERENCE:
     65% of the respondents are operator, 15% of the respondents are fitter, 10% of the
respondents are welder, 4% of the respondents are burner and 6% of the respondents are
painter.




                                          35
TABLE: 2.1.3         DISTRIBUTION OF THE RESPONDENTS-
                     DEPARTMENT WISE

                                                  No. of
          S. No          Particulars           respondents       Percentage
             1    Loader Assembly                   40               40
             2    Axle Plant                        15               15
             3    Dumber FABN                       30               30
             4    Tool Room                         5                 5
             5    FOP Paint                         10               10
                  Total                             100             100

CHART: 2.1.3         DISTRIBUTION OF THE RESPONDENTS-
                     DEPARTMENT WISE




INFERENCE:
              It is found from the above table 40% of the respondents are loader
assemble, 15% of the respondents are axle plant, 30% of the respondents are dumber
FABN, 5% of the respondents are tool room and 10% of the respondents are FOP paint.




                                         36
TABLE: 2.1.4          DISTRIBUTION OF THE RESPONDENTS-
                      MARTIAL STATUS

                                                  No. Of
              S. No        Particulars         respondents      Percentage
                 1           Single                 18              18
                 2          Married                 82              82
                               Total               100             100



CHART: 2.1.4          DISTRIBUTION OF THE RESPONDENTS-
                      MARTIAL STATUS




INFERENCE:
       It is found from the above tables 18% of the respondents are single and 82% of
the respondents are married.




                                          37
TABLE: 2.1.5           DISTRIBUTION OF THE RESPONDENTS-
                       QUALIFICATION WISE

                                                           No. of
  S. No                   Particulars                   respondents        Percentage
             th
     1     10                                                30                30
     2     12th                                              34                34
     3     Diploma                                           16                16
     4     PG                                                 2                 2
     5     Others                                            18                18
                            Total                            100               100



CHART: 2.1.5           DISTRIBUTION OF THE RESPONDENTS-
                       QUALIFICATION WISE




INFERENCE:
       It is inferred from the above table that 30% of the respondents have qualified in
10th, 34% of the respondents have qualified in 12th, 16% of the respondents have qualified
in diploma, 2% of the respondents have in PG level and 18% of the respondents have
qualified in others.




                                           38
TABLE: 2.1.6           DISTRIBUTION OF THE RESPONDENTS-
                       EXPERIENCE WISE

                                               No. Of
         S. No       Particulars               respondents          Percentage
                 1   Up to 5 yrs                       6                 6
                 2   6-10 Yrs                          9                 9
                 3   11-15 Yrs                        11                11
                 4   16-20 Yrs                        15                15
                 5   >20 Yrs                          59                59
                     Total                            100              100




CHART: 2.1.6           DISTRIBUTION OF THE RESPONDENTS-
                       EXPERIENCE WISE




INFERENCE:
              It is inferred from the above table 6% of the respondent belongs up to 5
years’ experience level, 9% of the respondents between 6-10 years experience level, 11%
of the respondents between 11-15 years, 15% of the respondents between 16-10 years
level and 59% of the respondents above 20 years experience level.



                                          39
TABLE: 2.1.7               AWARE OF THE SAFETY SYSTEM


                                                No. Of
             S. No       Particulars         respondents      Percentage
                1           Yes                  100              100
                2            No                   0                0
                           Total                 100              100



CHART: 2.1.7               AWARE OF THE SAFETY SYSTEM




INFERENCE:
     100% of the respondents are aware of the safety system prevailing in factory.




                                        40
TABLE: 2.1.8                 WORK PERMIT SYSTEM


                                                  No. Of
             S. No        Particulars          respondents        Percentage
                1            Yes                    52                52
                2             No                    48                48
                            Total                  100                100



CHART: 2.1.8                 WORK PERMIT SYSTEM




INFERENCE:
       58% of the respondents are satisfied with their work permit systems and 42% of
the respondents are unsatisfied with their work permit systems.




                                          41
TABLE: 2.1.9                  SAFETY IN TOOL BOX MEETING


                                                  No. Of
             S. No          Particulars        respondents   Percentage
                1     Yes                           90           90
                2     No                            10           10
                              Total                100           100




CHART: 2.1.9                  SAFETY TOOL BOX MEETING




INFERENCE:
       90% of the respondents have agreed with their tool box meeting and 10% of the
respondents have disagreed with their tool box meeting.




                                          42
TABLE: 2.1.10                CONTROL MEASURE TO ENSURE SAFETY


                                                   No. Of
             S. No         Particulars          respondents     Percentage
                1             Yes                    86             86
                2              No                    14             14
                             Total                  100             100


CHART: 2.1.10                CONTROL MEASURE TO ENSURE SAFETY




INFERENCE:
       It is inferred from the above table 86% of the respondents have agreed with their
proper control systems and 14% of the respondents have disagreed with their proper
control systems.




                                           43
TABLE: 2.1.11                IMPORTANCE OF SAFETY IS
                            COMMUNICATED TO THE EMPLOYEES
                                                    No. Of
       S. No            Particulars              respondents        Percentage
                Observance of the safety
         1      weeks                                 76                 76
         2      Safety competitions                   78                 78
         3      Talks on safety                       82                 82
                Booklet in
         4      Boards/Slogans                         69                69
         5      Booklets                               14                14
         6      House Magazines                        14                14
         7      Visual Displays                        33                33
                Total                                 100               100


CHART: 2.1.11                 IMPORTANCE OF SAFETY IS
                             COMMUNICATED TO THE EMPLOYEES




INFERENCE:
       76% they agree with safety weeks, 78% they agree with safety competitions, 82%
they agree with talks on safety, 69% they agree with bullet in boards, and each 14% they
agree with booklets, house magazines and 33% they agree with visual displays.

TABLE: 2.1.12                REDUCE THE RISK OF HAVING ACCIDENTS
                                           44
No. Of
        S. No         Particulars                respondents         Percentage
           1     Strongly agree                        7                   7
           2     Agree                                82                  82
           3     Disagree                              5                   5
           4     Strongly Disagree                     6                   6
                         Total                       100                 100


CHART: 2.1.12                REDUCE THE RISK OF HAVING ACCIDENTS




INFERENCE:
       It is inferred from the above table that 7% of the respondents have strongly
agreed with their reduce the accidents, 82% of the respondents have agree, 5% of the
respondents have disagree and 6% of the respondents have strongly disagree.




TABLE: 2.1.13                  ASSES THE RISK RATING IN WORK
                                           45
No. of
        S. No          Particulars             responsibility      Percentage
           1     Strongly agree                       6                 6
           2     Agree                               81                81
           3     Disagree                             9                 9
           4     Strongly disagree                    4                 4
                          Total                     100               100


CHART: 2.1.13                 ASSES THE RISK RATING IN WORK




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their asses the risk rating in work , 81% of the respondents have agree, 9%
of the respondents have disagree and 4% of the respondents have strongly disagree.




                                          46
TABLE: 2.1.14                ADEQUATE NUMBER OF TRAINING
                            PROGRAMS


                                                 No. Of
        S. No          Particulars           responsibility     Percentage
           1     Strongly agree                     6                6
           2     Agree                             77               77
           3     Disagree                          13               13
           4     Strongly disagree                  4                4
                          Total                   100              100



CHART: 2.1.14                ADEQUATE NUMBER OF TRAINING
                            PROGRAMS




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their adequate number of training programs on safety , 77% of the
respondents have agree, 13% of the respondents have disagree and 4% of the
respondents have strongly disagree.


                                        47
TABLE: 2.1.15                PROGRAMS CONDUCTED ON SAFETY


                                                  No. Of
        S. No          Particulars            responsibility      Percentage
           1     Strongly agree                      6                 6
           2     Agree                              76                76
           3     Disagree                           14                14
           4     Strongly disagree                   4                 4
                          Total                    100               100



CHART: 2.1.15         PROGRAMS CONDUCTED ON SAFETY




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their programs conducted on safety, 76% of the respondents have agree,
14% of the respondents have disagree and 4% of the respondents have strongly disagree.




                                         48
TABLE: 2.1.16          TRAINING NEEDS IDENTIFIED FOR THE
                      EMLOYEES


                                                  No. of
        S. No          Particulars            responsibility      Percentage
           1     Strongly agree                      6                 6
           2     Agree                              83                83
           3     Disagree                            8                 8
           4     Strongly disagree                   3                 3
                          Total                    100               100


CHART: 2.1.16          TRAINING NEEDS IDENTIFIED FOR THE
                      EMLOYEES




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their training needs, 83% of the respondents have agree, 8% of the
respondents have disagree and 3% of the respondents have strongly disagree.




                                         49
TABLE: 2.1.17         SAFETY RULES, INSTRUCTIONS HAVE BEEN
                      DISPLAYED

                                                    No. of
        S. No          Particulars              responsibility     Percentage
           1     Strongly agree                        6                6
           2     Agree                                80               80
           3     Disagree                              9                9
           4     Strongly disagree                     5                5
                          Total                      100              100


CHART: 2.1.17         SAFETY RULES, INSTRUCTIONS HAVE BEEN
                      DISPLAYED




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their safety rules, instructions have been displayed, 80% of the respondents
have agree, 9% of the respondents have disagree and 5% of the respondents have
strongly disagree.




                                          50
TABLE: 2.1.18          LAY OUT OF WORK PLACE


                                               No. of
                 S. No      Particulars    responsibility   Percentage
                   1     Strongly agree          6              6
                   2     Agree                   83             83
                   3     Disagree                8              8
                         Strongly
                   4     disagree                3              3
                              Total             100            100




CHART: 2.1.18          LAY OUT OF WORK PLACE




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their layout of work place have been properly designed to avoid the
accidents, , 83% of the respondents have agree, 8% of the respondents have disagree and
3% of the respondents have strongly disagree.



                                          51
TABLE: 2.1.19a        INTEGRATED SAFETY SYSTEM


                                                   No. of
             S. No        Particulars           respondents    Percentage
                1            Yes                     35            35
                2             No                     65            65
                            Total                   100           100




CHART: 2.1.19a        INTEGRATED SAFETY SYSTEM




INFERENCE:
       35% of the respondents have agreed with their integrated safety system and 65%
of the respondents have disagreed with their integrated safety system.




                                           52
TABLE: 2.1.19b       ADHERENCE TO THE SYSTEM IS GOOD


                                                  No. of
        S. No          Particulars            responsibility      Percentage
           1     Strongly agree                     5                 14
           2     Agree                             20                 57
           3     Disagree                           6                 17
           4     Strongly disagree                  4                 11
                          Total                    35                100


CHART: 2.1.19b        ADHERENCE TO THE SYSTEM IS GOOD




INFERENCE:
       It is inferred from the above table that 14% of the respondents have strongly
agreed with their adherence system, 57% of the respondents have agree, 17% of the
respondents have disagree and 11% of the respondents have strongly disagree.




TABLE: 2.1.20a       FIRST AID BOXES ARE AVAILABLE
                                         53
No. Of
            S. No           Particulars         respondents     Percentage
               1      Yes                            31              31
               2      No                             69              69
                              Total                 100             100



CHART: 2.1.20a        FIRST AID BOXES ARE AVAILABLE




INFERENCE:
       31% of the respondents have agreed with their first aid boxes are available at the
work place and 69% of the respondents have disagreed.




TABLE: 2.1.20b        ADEQUATE MEDICINES AVAILABLE

                                           54
No. of
        S. No          Particulars           responsibility     Percentage
           1     Strongly agree                    4                13
           2     Agree                            10                32
           3     Disagree                         13                42
           4     Strongly disagree                 4                13
                          Total                   31               100



CHART: 2.1.20b ADEQUATE MEDICINES AVAILABLE




INFERENCE:
       It is inferred from the above table that 13% of the respondents have strongly
agreed with their adequate medicines are available in work place, 32% of the
respondents have agree, 42% of the respondents have disagree and 13% of the
respondents have strongly disagree.

TABLE: 2.1.21        LIGHTING FACILITIES PROVIDED TO THE
                     WORKPLACE
                                        55
No. of
        S. No          Particulars            responsibility     Percentage
           1     Strongly agree                      6                6
           2     Agree                              85               85
           3     Disagree                            5                5
           4     Strongly disagree                   4                4
                          Total                    100              100



CHART: 2.1.21        LIGHTING FACILITIES PROVIDED TO THE
                     WORKPLACE




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their adequate lighting facilities provided to the work place, 85% of the
respondents have agree, 5% of the respondents have disagree and 4% of the respondents
have strongly disagree.

TABLE: 2.1.22        SAFETY VALVES HAVE BEEN PROVIDED



                                         56
No. of
        S. No          Particulars              responsibility     Percentage
           1     Strongly agree                        7                7
           2     Agree                                84               84
           3     Disagree                              5                5
           4     Strongly disagree                     4                4
                          Total                      100              100


TABLE: 2.1.22         SAFETY VALVES HAVE BEEN PROVIDED




INFERENCE:
       It is inferred from the above table that 7% of the respondents have strongly
agreed with their safety valves provided at the pressure vessels, 84% of the respondents
have agree, 5% of the respondents have disagree and 4% of the respondents have
strongly disagree.




TABLE: 2.1.23         NOISE LEVEL MONITORED


                                          57
No. of
        S. No          Particulars             respondents        Percentage
           1     Strongly agree                      6                 6
           2     Agree                              24                24
           3     Disagree                           64                64
           4     Strongly disagree                   6                 6
                          Total                    100               100


CHART: 2.1.23        NOISE LEVEL MONITORED




INFERENCE:
       It is inferred from the above table that 6% of the respondents have strongly
agreed with their noise level is regularly monitored and controlled at the work place,
24% of the respondents have agree, 64% of the respondents have disagree and 6% of the
respondents have strongly disagree.


TABLE: 2.1.24        FULL FLEDGED MEDICAL CENTRE

        S. No           Particulars                No. of         Percentage
                                         58
respondents
           1     Strongly agree                       4                   4
           2     Agree                               25                  25
           3     Disagree                            65                  65
           4     Strongly disagree                    6                   6
                          Total                     100                 100


TABLE: 2.1.24        FULL FLEDGED MEDICAL CENTRE




INFERENCE:
       It is inferred from the above table that 4% of the respondents have strongly
agreed with their full fledged medical centre, 25% of the respondents have agree, 65% of
the respondents have disagree and 6% of the respondents have strongly disagree.




TABLE: 2.1.25        ALL ACCIDENTS AND NEAR-MISSES ARE
                     FORMALLY INVESTIGATED


                                          59
No. of
        S. No          Particulars             respondents       Percentage
           1     Strongly agree                      9                9
           2     Agree                              91               91
           3     Disagree                            0                0
           4     Strongly disagree                   0                0
                          Total                    100              100



CHART: 2.1.25        ALL ACCIDENTS AND NEAR-MISSES ARE
                     FORMALLY INVESTIGATED




INFERENCE:
       It is inferred from the above table that 9% of the respondents have strongly
agreed with their accidents and near-misses are formally investigated, 91% of the
respondents have agree, 0% of the respondents have disagree and 6% of the respondents
have strongly disagree.


TABLE: 2.1.26        OPENION ABOUT SAFETY FACILITIES ARE
                     PORVIDED
        S. No             Particulars             No. of         Percentage
                                         60
respondents
            1    Highly satisfied                      7                   7
            2    Satisfied                            86                  86
            3    Dissatisfied                          5                   5
            4    Highly Dissatisfied                   2                   2
                            Total                    100                 100



CHART: 2.1.26         OPENION ABOUT SAFETY FACILITIES ARE
                      PORVIDED




INFERENCE:
       It is inferred from the above table that 7% of the respondents are highly satisfied
with their safety measures provided by the company, , 86% of the respondents have
agree, 5% of the respondents have disagree and 2% of the respondents have strongly
disagree.




                           2.2.1 CHI-SQUARE TEST


                                           61
TABLE 2.2.1                 AGE AND FIRST AID BOXES


Null Hypothesis (H0)               : There is no significant relationship between
                                   age and first aid boxes.


Alternative Hypothesis (H1)        : There is a significant relationship between age
                                   and first aid boxes.


Age and         Up to 20   21-30      31-40       41-50       >50               Total
First Aid
Boxes
Strongly           0          2           0           1             3               6
Agree
Agree              0          3           5           8             9              25


Disagree           0          2           7           39            17             65


Strongly           0          1           0           2             1               4
Disagree
Total              0          8          12           50            30             100




        Observed                    Expected                        (Oi-Ei)2/Ei
    Frequency(Oi)                  Frequency(Ei)
            0                             0                                0
            2                           0.48                              4.8
            0                           0.72                             0.72

                                        62
1                            3                          1.3
            3                           1.8                         0.8
            0                            0                           0
            3                            2                          0.5
            5                            3                          1.3
            8                          12.5                        1.62
            9                           7.5                        0.83
            0                            0                           0
            2                           5.2                        1.97
            7                           7.8                        0.08
           39                          32.5                         1.3
           17                          19.5                        0.32
            0                            0                           0
            1                          0.32                         1.4
            0                          0.48                        0.48
            2                            2                           0
            1                           1.2                        0.03




CHI - SQUARE TEST
The formula for
                      Ψ2   =   Σ (Oi-Ei) 2 / Ei
Calculated χ2 value        =   17.45
Degree of Freedom          =   (R-1) (C-1)
                           =   (4-1) (5-1)
                           =   12
Table value χ2             =   21.03
      Result               =   Calculated χ2 value 17.45 < Table value χ2
                               21.03 at 5% level of significant.
                                       63
INFERENCE
          It is found from the above table that calculated value is less than the
table value at 12 degree of freedom. Hence, Null hypothesis (H 0) accepted. It
concluded that there is no significant relationship between age and first aid
boxes.




TABLE 2.2.2            EXPERIENCE AND NOISE LEVEL


Null Hypothesis (H0)               : There is no significant relationship between
                                   experience and noise level.


Alternative Hypothesis (H1)        : There is a significant relationship between
                                   experience and noise level.


Experience Up to 5      6-10 Yrs    11-15 Yrs   16-20 Yrs    >20 Yrs     Total
and Noise    Yrs
Level

                                        64
Strongly        1   1            0          0      2            4
Agree


Agree           3   3            4          8     10           28



Disagree        1   5            6          7     46           65



Strongly        1   0            1          0      1            3
Disagree


Total           6       9       11          15    59
                                                               100




        Observed             Expected            (Oi-Ei)2/Ei
    Frequency(Oi)           Frequency(Ei)

            1                   0.24                   2.41
            1                   0.36                   1.14
            0                   0.44                   0.44
            0                    0.6                    0.6
            2                   2.36                    0.5
            3                   1.68                   1.04
            3                   2.52                   0.09
            4                   3.08                   0.27
            8                    4.2                   3.44
           10                   16.5                   2.57
            1                    3.9                   2.16
            5                   5.85                   0.12
            6                    7.2                   0.18
            7                    9.8                   0.78
           46                   38.4                   1.53
            1                   0.18                   3.74
                                65
0                            0.27                        0.27
              1                            0.33                        1.36
              0                            0.45                        0.45
              1                            1.77                        0.34




CHI - SQUARE TEST
The formula for
                      Ψ2     =     Σ (Oi-Ei) 2 / Ei
Calculated χ2 value         =      23.43
Degree of Freedom           =      (R-1) (C-1)
                            =      (4-1) (5-1)
                            =      12
Table value χ2              =      21.03
         Result              =     Calculated χ2 value 23.43 > Table value χ2
                                   21.03 at 5% level of significant.




INFERENCE
            It is found from the above table that calculated value is greater than
the table value at 12 degree of freedom. Hence, Null hypothesis (H 0) rejected. It
concluded that there is significant relationship between experience and noise
level.




                                           66
TABLE 2.2.3            TRAINING AND SATISFACTION


Null Hypothesis (H0)               : There is no significant relationship between
                                   training and satisfaction.


Alternative Hypothesis (H1)        : There is a significant relationship between
                                   training and satisfaction.


Experience Up to 5      6-10 Yrs    11-15 Yrs    16-20 Yrs      >20 Yrs   Total
and Noise    Yrs
Level

Strongly           1       1             0            0             2        4
Agree


Agree              3       3             4            8             10      28



Disagree           1       5             6            7             46      65



Strongly           1       0             1            0              1       3
Disagree

                                        67
Total           6   9       11          15    59
                                                           100




        Observed         Expected            (Oi-Ei)2/Ei
    Frequency(Oi)       Frequency(Ei)

            1               0.24                2.41
            1               0.36                1.14
            0               0.44                0.44
            0                0.6                 0.6
            2               2.36                 0.5
            3               1.68                1.04
            3               2.52                0.09
            4               3.08                0.27
            8                4.2                3.44
           10               16.5                2.57
            1                3.9                2.16
            5               5.85                0.12
            6                7.2                0.18
            7                9.8                0.78
           46               38.4                1.53
            1               0.18                3.74
            0               0.27                0.27
            1               0.33                1.36
            0               0.45                0.45
            1               1.77                0.34




CHI - SQUARE TEST

                             68
The formula for
                      Ψ2     =     Σ (Oi-Ei) 2 / Ei
Calculated χ2 value         =      23.43
Degree of Freedom           =      (R-1) (C-1)
                            =      (4-1) (5-1)
                            =      12
Table value χ2              =      21.03
         Result              =     Calculated χ2 value 23.43 > Table value χ2
                                   21.03 at 5% level of significant.




INFERENCE
            It is found from the above table that calculated value is greater than
the table value at 12 degree of freedom. Hence, Null hypothesis (H 0) rejected. It
concluded that there is significant relationship between experience and noise
level.




                                 CHAPTER III

                                           69
3.1       SUMMARY OF FINDINGS


This chapter deals with the main findings which are mainly drawn from the previous
chapter (Analysis and Interpretations). These main findings are very important for this
study to come out with the appropriate suggestions. The followings are main findings
drawn from the study.


MAIN FINDINGS
   •   Majority(50%) of the respondents working in Caterpillar age between 41-50
   •   Majority (65%) of the respondents are operator.
   •   Majority (40%) of the respondents are under come loader assembly department.
   •   More than three fourth of the employees (82%) were married.
   •   100% of the respondents working in Caterpillar were male.
   •   Majority of the respondents (34%) educational status were +2.
   •   Majority of employees (59%) had served at caterpillar for more than twenty
       years.
   •   100% of the respondents are aware of safety system prevailing n the factory
   •   Nearly half of the employees (52%) have been provided with work permit
       systems in their factory
   •   Majority of the respondents (90%) are provided with priority for safety in Tool
       box meeting.

   •   86% of the respondents say that they have been provided with proper control
       measure to ensure safety in their work place.
   •   Nearly half of the employees (82%) of respondents the importance of safety is
       communicated through talks on safety.
   •   Nearly three fourth (82%) of the employees agree that safety measures will
       reduce the Risk of having accidents.
   •   Nearly half of the respondents (81%) accepted that there is a system in a place to
       asses the risk rating in their day to day work.
   •   77% of the respondents feel that they have been given adequate number of
       training programs in Caterpillar.
                                            70
•   Three fourth of the respondents (76%) say’s that the programs conducted on
    safety is very effective.
•   Majority of the respondents (83%) think that the training programs as per
    identified training needs.
•   80% of the respondents agree that safety rules, instructions have been displayed
    everywhere in the factory permanently.
•   Nearly three fourth (83%) of the employees accepted that the layout of the work
    place have been properly designed to avoid accidents.
•   65% of the employees feel that there is no integrated safety systems provided in
    machines and they suggested that company can adhere to a system which is
    good.

•   More than half of the respondent (69%) says that there is adequate number of
    first aid boxes available in the factory.
•   85% of the respondents are agreed with their lighting facilities provided to the
    employees at work place.

•   More than half of the respondents agree that the safety valves have been
    provided with pressure vessels.
•   Nearly three fourth of the employees strongly disagree that the noise level is
    regularly monitored and controlled in the factory.
•   Nearly three fourth of the employees (65%) feels that the company do not have
    the full fledged first aid provision.
•   Majority of the employees (91%) agree that all accidents and all near misses are
    formally investigated.
•   86% of the respondents are satisfied with the overall safety provisions provided
    in the factory.




                                3.2 SUGGESTIONS


                                            71
•   Adequate number of first aid boxes should be provides in every
    department and also provides an adequate number of medicines in the
    work place.

•   The companies try to provide different way of awareness programs on
    safety.

•   Full fledged first aid centre should be improved and maintained.

•   Noise level should be control and monitor regularly.

•   Safety valves should be providing to pressure vessels.

•   Electric circuit and electric wires should be checked, maintained properly.

•   The integrated safety system of the machines should be improved.

•   Work permit system to be implemented.

•   Company should asses the equipments used by every employees.




                                72
3.3    CONCLUSION

           A study was conducted on the safety management system at CIPL.


           A majority of 86% of the respondents were found to be satisfied with the
safety measures at CIPL, 7% were highly satisfied, and only 5% were dissatisfied , 2% of
them highly dissatisfied.
Most of the employees feel company should improve their first aid centre and adequate
medicines are easily available in all work place Employees also feel noise level should be
monitored and controlled.
The company should be given improved work permit system to employees.




                                           73
BIBLIOGRAPHY

BOOKS:

   •   Industrial Safety                             - J. Nagaraj and V.Ramachandra Rao

   •   Industrial Relations                                       -ArunMonapa
   •   Human Resource and Personnel Management
       Fourth Edition, Tata Mc Graw Hill Publishing               -K. Aswathappa
   •   Organization Behaviour                                      - L.M. Prasad

   •   Personnel Management                                       - Dr. Gupta


websites


       http://en.wikipedia.org/wiki/Safety_culture


       http://www.theiplgroup.com/safety culture-review


       http://safetyatworkblog.wordpress.com




                                               74
APPENDIX


      “A STUDY ON SAFETY MANAGEMENT SYSTEMS WITH
   REFERENCE TO CATERPILLAR INDIA PRIVATE LIMITED”
                                            QUESTIONNAIRE


Personal Details
Age                        : [ ] up to 20           [ ] 21-30       [ ] 31-40       [ ] 41-50
                                     [ ]>50
Designation                :
Department                 :
Martial Status             : [     ] Single         [   ] Married
Gender                     : [     ] male           [ ] female
Educational Level          : [     ] 10th           [   ] 12th      [ ] Diploma
                               [   ] UG             [ ] PG          [ ] Others
Length of Service          : [     ] up to 5 Yrs    [ ] 6-10 Yrs    [ ] 11-15 Yrs
                               [   ] 11-15 Yrs      [ ] >20 Yrs


   1. Are you aware of the safety system prevailing in your factory?

                 [ ] Yes             [ ] No


   2. Do you have any work permit systems in your factory?

                 [   ] Yes           [ ] No


   3. Is there any priority for safety in Tool Box Meeting?


                                                   75
[   ]   Yes     [ ] No


4.   Is there any proper control measure to ensure safety at your work place?

             [   ]   Yes     [ ] No


5. How the importance of safety is communicated to the employees? Please tick the
     appropriate answer.

                 •    Observance of the safety weeks

                 •    Safety competitions

                 •    Talks on Safety

                 •    Bullet in Boards/Slogans

                 •    Pamphlets

                 •    Booklets

                 •    House Magazines

                 •    Visual Displays



6. A safety measures reduce the risk of having accidents in your work place.

             [ ] Agree       [ ] Strongly Agree   [ ] Disagree [ ] Strongly Disagree


7. There is a system/method in place to asses the risk rating in your day to day
     work.

             [ ] Agree       [ ] Strongly Agree   [ ] Disagree [ ] Strongly Disagree


8.   Adequate number of training programs on safety is conducted for the
     employees of caterpillar.


                                            76
[ ] Agree       [ ] Strongly Agree     [ ] Disagree [ ] Strongly Disagree


9. The programs conducted on safety are very effective.

           [ ] Agree       [ ] Strongly Agree     [ ] Disagree [ ] Strongly Disagree


10. Training programs are conducted as per training needs identified for the
   employees

           [ ] Agree       [ ] Strongly Agree     [ ] Disagree [ ] Strongly Disagree




11. A safety rules, instructions have been displayed everywhere in the factory
   permanently

           [ ] Agree       [ ] Strongly Agree     [ ] Disagree [ ] Strongly Disagree


12. The layouts of the workplace have been properly designed to avoid accidents.

           [ ] Agree       [ ] Strongly Agree     [ ] Disagree [ ] Strongly Disagree


13. Has any integrated safety system been provided in the machines?

           [ ] Yes         [ ] No
   If yes, adherence to the systems is good
                     [ ] Agree      [ ] Strongly Agree   [ ] Disagree [ ] Strongly
   Disagree


14. Adequate numbers of first Aid boxes are available at the work place.

           [ ] Yes               [ ] No
   If yes, adequate numbers of medicines are available
           [ ] Agree       [ ] Strongly Agree     [ ] Disagree [ ] Strongly Disagree


15. Adequate lighting facilities have been provided at the workplace.
                                          77
[ ] Agree      [ ] Strongly Agree      [ ] Disagree [ ] Strongly Disagree


16. Safety valves have been provided at the pressure vessels?
           [ ] Agree      [ ] Strongly Agree      [ ] Disagree [ ] Strongly Disagree


17. Company have a full-fledged medical centre

           [ ] Agree      [ ] Strongly Agree      [ ] Disagree [ ] Strongly Disagree


18. Noise level is regularly monitored and controlled at the work place

           [ ] Agree      [ ] Strongly Agree      [ ] Disagree [ ] Strongly Disagree




19. All accidents and all near-misses are formally investigated

           [ ] Agree      [ ] Strongly Agree      [ ] Disagree [ ] Strongly Disagree


20. Are you satisfied with the safety measures provided by your company?

           [   ] Highly Satisfied [ ] Satisfied    [ ] Dissatisfied   [ ] Highly
   Dissatisfied




                                        78

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The effectiveness of safety mgt system in caterpiller

  • 1. CHAPTER 1 INTRODUCTION 1.1 INTRODUCTION TO THE STUDY Safety is inevitable to any organization when employees are involved. An organization’s responsibility to its employees extends beyond the payment of wages for their services. The employee’s safety both on and off the job within the organization is a vital concern of the employer. Providing a safe and healthy environment is a pre- requisite for any productive effort. This research deals with the study on the safety provided to the employees at Caterpillar. Introduction to Safety- Begin this course with an overview of effective safety and health programs and an understanding of their importance to both employers and employees. Discover methods for implementing safety programs in the industrial workplace. Walking and working Surfaces- Identify common hazards that may increase the probability of workplace accidents. Study proper “House Keeping” and the correct use of ladders and stairways. Identify when to use covers and guardrails and the steps that can be taken to minimizing slipping, tripping, and falling in the workplace. Prevention and Protection Plans- Study the importance of an effective emergency management plan in reducing workplace injuries and deaths. Learn that an effective safety plan includes proper and clearly marked exits, functioning and regularly maintained fire-fighting equipment and employee training programs. Employee Safety: 1
  • 2. A top priority for any employer should be to take the time and initiative to help protect their employees. If an employee becomes injured at work, your business may suffer. Machines in the workplace can pose operating hazards. From minor cuts and abrasion to serious lacerations, exposure to machine operations can be detrimental to life, health and productivity. It is highly recommended that you purchase machinery equipped with guarding or that the guards on existing equipment left intake and employees be trained to use them. Hazards Materials Chemicals and solvents in the workplace can create hazardous conditions. Some combinations of common cleaning chemicals can cause serious life threatening conditions. • Use a designated storage place for chemicals • Read the labels on your products and become familiar with material safety data sheets. Personal Protective Equipment (PPE) When the workplace hazards cannot be eliminated or reduced, personal protective equipment may be necessary. PPE does not eliminate a hazardous situation; it simply creates a protective barrier between the employee and the hazard. Equipment can be in the form of; Non respirators  Safety glasses or goggles  Gloves  Boots  Hearing protection  Hardhats  Helmet  Earplug  Apron 2
  • 3.  Leg guard  Arm shield  Wind shield Respirators  Dust respirators  Chemical respirators  Welding fume  Visual air system Definitions of safety System Safety Engineering and Management states that safety may be defined “as a quality of a system that allows the system to function under pre-determined conditions with an acceptable minimum of accidental loss”. Air services Australia (2001, AA-Safe-001, p.1) define safety as “Being in a situation where the risks of an aircraft accident or air safety incident are reduced to a level as a low as reasonable practicable” reinforcing the proposition that the working definition of Safety includes risk management. Safety can be framed for the purposes of this paper as a characteristic of a system that does not permit unacceptable risks to be undertaken with the goal of injury free operations.  The condition of being safe; freedom from danger, risk, or injury.  the state of being certain that adverse effects will not be caused by some agent under defined conditions  Occupational safety is concerned with risks in areas where people work: offices, manufacturing plants, farms, construction sites, and commercial and retail facilities. Public safety is concerned with hazards in the home, in travel and recreation, and in other situations that do not fall within the scope of occupational safety. 1.2 NEED AND IMPORTANCE OFTHE STUDY 3
  • 4. 1. This study would give an overview of the safety measures existing at Caterpillar. 2. Since safety and welfare are two important elements essential for improving the productivity of an organization, a study on the existing safety measures would help the organization perform better. 3. This study would throw light on the perception of the employees regarding safety. 4. Caterpillar can identify the areas where it can improve so as to improve the performance of the employees. 5. This study would also help to analyze if there is dependence between departments and categories and the level of satisfaction of safety measures 6. Suggest provisions of more safety measures. 4
  • 5. 1.3 SCOPE OF THE STUDY The study undertaken for CATERPILLAR aims to find the reason for safety measures. This study is done with the help of a questionnaire which contains questions which probe into the details so as to find the reason of their choice. Safety and welfare are two important elements essential for improving the productivity of an organization, a study on the existing safety measures would help the organization perform better. Safety measures may be viewed as a total concept and as a relative concept. The total concept is a desirable state of existence involving the physical, mental, moral and economical well-being. These four elements together constitute the structure of the welfare implies the welfare of man, his family and community. 5
  • 6. 1.4 OBJECTIVES OF THE STUDY Primary Objectives: A study on “The Effectiveness of Safety Management System” in Caterpillar India Private Ltd. Secondary Objectives:  To find out whether adequate safety measures are provided to the employees  To find out the fulfillment of safety measures to employees  To analyze the safety measures followed by the contract laborers  To observe the employees satisfaction towards the safely training program  To find out the employees expectation towards safety measures in this company. 6
  • 7. 1.5 LIMITATIONS OF THE STUDY  The study is applicable to “CATERPILLAR PVT LIMITED”  The respondents have replied to the queries recalling from their memory. Therefore recall bias and personal bias are possible.  The sample size was limited to 100.  Since the data was collected using a schedule, the interviewer’s inability to understand and record the responses correctly is possible.  The respondents were unable or unwilling to give a complete and accurate response to certain questions. 7
  • 8. 1.6 COMPANY PROFILE For more than 80 years, Caterpillar has been building the world’s infrastructure and, in partnership with network of Cat® dealers worldwide, has helped drive positive and sustainable change on every continent. They are a global company, with hundreds of locations worldwide to serve and support customer base, and respond quickly to their needs . Corporate Profile For more than 80 years, Caterpillar Inc. has been making progress possible and driving positive and sustainable change on every continent. With 2008 sales and revenues of $51.324 billion, Caterpillar is the world’s leading manufacturer of construction and mining equipment, diesel and natural gas engines and industrial gas turbines. The company also is a leading services provider through Cat Financial Services, Cat Remanufacturing Services, Cat Logistics Services and Progress Rail Services. They are proud to be a leader in building the world’s infrastructure, and in enabling progress for millions of people around the globe. They manufacture more than 300 products in 23 countries and serve customers in nearly 200 countries. They are headquartered in Peoria, Illinois. The History of Caterpillar 1890. Benjamin Holt and Daniel Best experimented with various forms of steam tractors for use in farming. They did so separately, with separate companies. 1904. Holt's first steam track-type tractor. 1906. Holt's first gas track-type tractor. 1915. Holt "Caterpillar®" track-type tractors are used by the Allies in World War I. 1925. The Holt Manufacturing Company and the C. L. Best Tractor Co. merge to form Caterpillar Tractor Co. 8
  • 9. 1931. The first Diesel Sixty Tractor rolled off the assembly line in East Peoria, Illinois, with a new efficient source of power for track-type tractors. 1940. The Caterpillar product line now included motor graders, blade graders, elevating graders, terracers and electrical generating sets. 1942. Caterpillar track-type tractors, motor graders, generators sets and a special engine for the M4 tank are used by the United States in its war effort. 1950. Caterpillar Tractor Co. Ltd. in Great Britain is established, the first of many overseas operations created to help manage foreign exchange shortages, tariffs, import controls and better serve customers around the world. 1953. In 1931, the company created a separate engine sales group to market diesel engines to other equipment manufacturers. This group was replaced in 1953 with a separate sales and marketing division to better serve the needs of a broad range of engine customers. Engine sales now account for approximately one-third of the company's total sales and revenues. 1963. Caterpillar and Mitsubishi Heavy Industries Ltd. form one of the first joint ventures in Japan to include partial U.S. ownership. Caterpillar Mitsubishi Ltd. started production in 1965, has been renamed Shin Caterpillar Mitsubishi Ltd., and is now the No. 2 maker of construction and mining equipment in Japan. 1981-83. the worldwide recession took its toll on Caterpillar, costing the company the equivalent of $1 million a day and forcing it to dramatically reduce employment. 1983. Caterpillar Leasing Company is expanded to offer equipment financing options to its customers worldwide and is renamed Caterpillar Financial Services Corporation. 1985-present. The product line continued to diversify to meet a variety of customer needs. More than 300 products are now offered, more than double the figure in 1981. 9
  • 10. 1986. The Caterpillar Tractor Co. changes its name to Caterpillar Inc. - a more accurate reflection of the enterprise's growing diversity. 1987. A $1.8 billion plant modernization program was launched to streamline the manufacturing process. 1990. The company decentralized its structure, reorganizing into business units responsible for return on assets and customer satisfaction. 1997. The company continued to expand, acquiring the U.K.-based Perkins Engines. With the addition of Germany's MaK Motoren the previous year, Caterpillar becomes the world leader in diesel engine manufacturing. 1998. The world's largest off-highway truck - the 797 - makes its debut at the Cat Proving Ground in Arizona. 1999. Caterpillar unveils new line of compact construction equipment at CONEXPO, world's largest construction show, in response to changing customer needs for smaller, more versatile construction equipment. 2000. Caterpillar celebrates its 75th anniversary. 2001. Caterpillar is the first company to globally launch 6 Sigma and deliver first-year benefits in excess of implementation costs. 2003. Caterpillar becomes the first engine manufacturer to offer a complete line of 2004 model year clean diesel engines fully compliant and certified by the U.S. Environmental Protection Agency (EPA). Caterpillar's breakthrough emissions control technology, known as ACERT®, is designed to comply with EPA standards without sacrificing performance, reliability or fuel efficiency. 2005. Demonstrating a pledge to sustainable development, Caterpillar responded to a number of tragedies around the world, including the Asian Tsunami disaster, hurricanes 10
  • 11. along the U.S. Gulf Coast and earthquakes in South Asia. In the face of each of these challenges, employees, dealers and corporate leaders alike joined together to build a promise of hope and growth for all those affected by donating machinery, money and resources for relief and recovery efforts. 2006. Benjamin Holt, one of Caterpillar Inc.'s founding fathers and designer of the first track-type tractor was recognized for his ingenuity and entrepreneurial spirit with an induction into the National Inventors Hall of Fame. 2006. Caterpillar Inc. subsidiary Caterpillar Logistics Services, Inc. (Cat Logistics) opens a new parts distribution center in the Lingang Industrial Area in Shanghai. 2006. Caterpillar launched a revised and updated Worldwide Code of Conduct and Enterprise Strategy. Serving new markets and new customers in new ways, Caterpillar welcomed the opportunity to experience unchartered growth across all business ventures. Mission Their mission is to enable economic growth through infrastructure And energy development, and provide solutions that protect people and preserve the planet. Vision Their vision is a world in which all people’s basic requirements—such as Shelter, clean water, sanitation and reliable power—are fulfilled in a way that sustains our environment. Strategy Their strategy is to provide work environments, products, services and solutions that make efficient use of the world’s natural resources and reduce unnecessary impacts on people, the environment and the economy. This means that they leverage resources, including technology and innovation to: 11
  • 12. Optimize the use of renewable resources • Minimize emissions • Maximize recycling • Promote and protect individual Safety and well-being • Minimize the use of energy, materials, water and land • Provide employment, education and training Sustainable Development Critical Success Factors (CSFs) Progress Culture Create a culture of sustainable development in all their business units and in all their daily work. Operations Be consistent with their sustainability principles and contribute to enterprise sustainable development goals. Business Opportunities Identify and pursue business growth opportunities created by sustainable development. Caterpillar Enterprise Goals to 2020 (Baseline 2006) Established in 2007, these aspirational, enterprise-wide goals focus on sustainability in every aspect of their business. 2020 Goals for Products, Services and Solutions • Reduce customer greenhouse gas emissions by 20% • Increase customer energy efficiency by 20% • Provide leadership in the safety of people in, on and around our products • Increase customer material efficiency by 20% 12
  • 13. 2020 Goals for Operations • Use alternative/renewable sources to meet 20% of their energy needs • Reduce recordable workplace injury rates to 0.6 and lost-time case rate due to injury to 0.15 • Increase energy efficiency by 25% • Design all new construction to meet Leadership in Energy and Environmental Design(LEED) or comparable green building criteria • Eliminate waste by reducing Hold water consumption flat waste generation and reusing or recycling all that remains • Reduce absolute greenhouse gas emissions from existing facilities by 25% 13
  • 14. 1.7 Industry Profile Indian Infrastructure sector is currently going through a vast transformation with the third largest road network of 3 million Km crisscross the country, the automobile revolution has more than doubled from 21.3 million at the beginning of 1990’s to 48.4 million by end of the decade. The Government has already embarked upon massive road construction projects, with national highway development from building the North-South and East-West corridors and golden quadrangle projects connecting major cities. Besides government’s decision to throw open the construction of roads, bridges and airports to private sector and allowing 100% foreign investment in real estate projects, has provided a boost to the construction industry as well as generate demand for construction machinery. The total investment of road and highway construction project is estimated as $40 billion turnover the next 15 years of which 20% is expected to be in construction machinery. Hence a total demand of $10 billion construction machinery is expected in next 20 years. The present market for construction machinery is estimated to $1312.17 million, out of which about 1% is imported. Indian construction machinery Industry is undergoing a rapid transformation from low volume, intensive use of equipment structure to high volume, and specific use one. The new housing and infrastructure ventures have generated substantial demand for construction machinery, manufacturing and servicing. While the previous trend was to forge joint venture associations with Indian companies, more and more multinational companies are now entering the Indian market on their own strength. The major manufacturers and importers of the estimated $1312.17 industry are:  Ashok Leyland  Atlas Copco (India) 14
  • 15.  B G Shirke Construction Equipment  Caterpillar India  Ingersoll Rand India  JCB India  Larsen & Toubro  Metso Minerals  Salgaocar Engineers  Schwing-Stetter India  Telco Construction Equipment  Terex Vectra Equipment  Voltas In India, Caterpillar languishes in fourth position in sales of diggers, loaders and other construction machines. The key Success Factors are: Focus on quality and operational efficiency From the outset, CIPL has had a strong focus on quality. To this end, it focused on implementing Six Sigma and the pursuit of operational excellence using Class A disciplines. Superior product development capabilities Caterpillar’s unique New Product Introduction (NPI) process gives guidance, direction and accountability to all stakeholders while ensuring its overall success. The cornerstone of this product development process is the customer validation exercise where machines are placed in a non-clinical environment and evaluated for more than 3,500 hours. The company uses tools like the Prediction of Estimated Reliability Growth Plan (PERG) and Statistical tools such as the Weibull Analysis for checking machine performance prior to launch. Such processes and tools enabled the company to successfully launch the backhoe loader, and assure success in a competitive market. World Wide Competitors of Caterpillar are:  Komatsu(Japan)  Hitachi(Japan) 15
  • 16.  CNH-Case new Holland(France)  John Deer(USA)  Volvo (Sweden). 16
  • 17. 1.8 REVIEW OF LITERATURE Definitions of safety  The condition of being safe; freedom from danger, risk, or injury.  the state of being certain that adverse effects will not be caused by some agent under defined conditions  Occupational safety is concerned with risks in areas where people work: offices, manufacturing plants, farms, construction sites, and commercial and retail facilities. Public safety is concerned with hazards in the home, in travel and recreation, and in other situations that do not fall within the scope of occupational safety. Introduction Introduction to safety- Being this course with an overview of effective safety and health programs and an understanding of their importance to both employers and employees .Discover methods for implementing safety programs in the industrial workplace. Employee safety: A top priority for any employer should be to take the time and initiative to help protect their employees becomes at work, your business may suffer. Machines in the work place can pose operating hazards. From minor cuts and abrasion to serious lacerations, exposure to machine operations can be detrimental to life, health and productivity. It is highly recommended that you purchased machinery equipped with guarding or that the guards on existing equipment left intake and employees be trained to use them. 17
  • 18. FACTORIES ACT, 1948 The Factories Act is a social legislation which has been enacted for occupational safety, health and welfare of workers at work places. This legislation is being enforced by technical officers i.e. Inspectors of Factories, Dy. Chief Inspectors of Factories who work under the control of the Chief Inspector of Factories and overall control of the Labour Commissioner, Government of National Capital Territory of Delhi SALIENT FEATURES OF THE ACT ARE:- 1. Approval of Factory Building Plans before construction/extension, under the Delhi Factories Rules, 1950. 2. Grant of Licenses under the Delhi Factories Rules, 1950, and to take action against factories running without obtaining License. 3. Renewal of Licenses granted under the Delhi Factories Rules, 1950, by the Dy. Chief Inspectors of Factories. 4. Inspections of factories by District Inspectors of Factories, for investigation of complaints, serious/fatal accidents as well as suo moto inspections to check compliance of provisions of this Act relating to :- 18
  • 19. I. He alt h II. Saf ety III . W elf are fac ilit ies IV. W or ki ng ho ur s V. E m pl oy me nt 19
  • 20. 1.CLEANLINESS:Every factory shall be kept clean and free from effluvia arising from any drain, privy or other, nuisance, and in particular - (a) accumulations of dirt and refuse shall be removed daily by sweeping or by any other effective method from the floors and benches of workrooms and from staircases and passages, and disposed of in a suitable manner; (b) The floor of every workroom shall be cleaned at least once in every week by washing, using disinfectant, where necessary, or by some other effective method; (c) where a floor is liable to become wet in the course of any manufacturing process to such extent as is capable of being drained, effective means of drainage shall be provided and maintained; (d) all inside walls and partitions, all ceilings or tops of rooms and all walls, sides and tops of passages and staircases shall - (ii) where they are painted otherwise than with washable water-paint or varnished, be repainted or re-varnished least once in every period of five years; (ii) Where they are painted or varnished or where they have smooth impervious surfaces, be cleaned at least once in every period of fourteen months by such method as may be prescribed; (iii) In any other case, be kept whitewashed or color-washed, and the whitewashing or color-washing shall be carried out at least once in every period of fourteen months; (d) All doors and window frames and other wooden or metallic frame work and shutters shall be kept painted or varnished and the painting or varnishing shall be carried out at least once in every period of five years; (e) The dates on which the processes required by clause (d) are carried out shall be entered in the prescribed register. (2) If, in view of the nature of the operations carried on in a factory or class or description of factories or any part of a factory or class or description of factories, it is 20
  • 21. not possible for the occupier to comply with all or any of the provisions of sub-section (1), the State Government may by order exempt such factory or class or description of factories or part from any of the provisions of that sub-section and specify alternative methods for keeping the factory in a clean state. 12. DISPOSAL OF WASTES AND EFFLUENTS. - (1) Effective arrangements shall be made in every factory for the treatment of wastes and effluents due to the manufacturing process carried on therein, so as to render them innocuous, and for their disposal. (2) The State Government may make rules prescribing the arrangements to be made under sub-section (1) or requiring that the arrangements made in accordance with sub- section (1) shall be approved by such authority as may be prescribed. 13. VENTILATION AND TEMPERATURE. - (1) Effective and suitable provision shall be made in every factory for securing and maintaining in every workroom - (a) adequate ventilation by the circulation of fresh air, and (b) Such a temperature as will secure to workers therein reasonable conditions of comfort and prevent injury to health; and in particular, - (i) walls and roofs shall be of such material and so designed that such temperature shall not be exceeded but kept as low as practicable; (ii) Where the nature of the work carried on in the factory involves, or is likely to involve, the production of excessively high temperatures such adequate measures as are practicable shall be taken to protect the workers there from, by separating the process which produces such temperatures from the workroom, by insulating the hot parts or by other effective means. (2) The State Government may prescribe a standard of adequate ventilation and reasonable temperature for any factory or class or description of factories or parts thereof and direct that [ lra-48 proper measuring instruments, at such places and in such 21
  • 22. position as may be specified, shall be provided and such records, as may be prescribed, shall be maintained; (3) If it appears to the Chief Inspector that excessively high temperatures in any factory can be reduced by the adoption of suitable measures, he may, without prejudice to the rules made under sub-section (2), serve on the occupier, an order in writing specifying the measures which, in his opinion, should be adopted, and requiring them to be carried out before a specified date. 14. DUST AND FUME. - (1) In every factory in which, by reason of the manufacturing process carried on, there is given off any dust or fume or other impurity of such a nature and to such an extent as is likely to be injurious or offensive to the workers employed therein, or any dust in substantial quantities, effective measures shall be taken to prevent its inhalation and accumulation in any workroom, and if any exhaust appliance is necessary for this purpose, it shall be applied as near as possible to the point of origin of the dust, fume or other impurity, and such point shall be enclosed so far as possible. (2) In any factory no stationary internal combustion engine shall be operated unless the exhaust is conducted into the open air, and no other internal combustion engine shall be operated in any room unless effective measures have been taken to prevent such accumulation of fumes therefore as are likely to be injurious to workers employed in the room. 15. ARTIFICIAL HUMIDIFICATION. - (1) In respect of all factories in which the humidity of the air is artificially increased, the State Government may make rules, - (a) prescribing standards of humidification; (b) Regulating the methods used for artificially increasing the humidity of the air, (c) Directing prescribed tests for determining the humidity of the air to be correctly carried out and recorded; (d) Prescribing methods to be adopted for securing adequate ventilation and cooling of the air in the workrooms. 22
  • 23. (2) In any factory in which the humidity of the air is artificially increased, the water used for the purpose shall be taken from a public supply, or other source of drinking water, or shall be effectively purified before it is so used. (3) If it appears to an Inspector that the water used in a factory for increasing humidity which is required to be effectively purified under sub-section (2) is not effectively purified he may serve on the manager of the factory an order in writing, specifying the measures which in his opinion should be adopted, and requiring them to be carried out before specified date. 16. OVERCROWDING. - (1) No room in any factory shall be overcrowded to an extent injurious to the health of the workers employed therein. (2) Without prejudice to the generality of sub-section (1), there shall be in every workroom of a factory in existence on the date of the commencement of this Act at least 9.9 cubic meters and of a factory built after the commencement of this Act at least 14.2 cubic meters or space for every worker employed therein, and for the purposes of this sub-section no account shall be taken of any space which is more than 4.2 meters above the level of the floor of the room. (3) If the Chief Inspector by order in writing so requires, there shall be posted in each workroom of a factory a notice specifying the maximum number of workers who may, in compliance with the provisions of this section, be employed in the room. (4) The Chief Inspector may by order in writing exempt, subject to such conditions, if any, as he may think fit to impose, any workroom from the provisions of this section, if he is satisfied that compliance therewith in respect of the room is unnecessary in the interest of the health of the workers employed therein. 17. LIGHTING. (1) In every part of a factory where workers are working or passing there shall be provided and maintained sufficient and suitable lighting, natural or artificial, or both. 23
  • 24. (2) In every factory all glazed windows and skylights used for the lighting of the workroom shall be kept clean on both the inner and outer surfaces and, so far as compliance with the provisions of any rules made, under sub-section (3) of section 13 will allow, free from obstruction. (3) In every factory effective provision shall, so far as is practicable, be made for the prevention of - (a) glare, either directly from a source of light or by reflection from a smooth or polished surface; (b) The formation of shadows to such an extent as to cause eye-strain or the risk of accident to any worker. (4) The State Government may prescribe standards of sufficient and suitable lighting for factories or for any class or description of factories or for any manufacturing process. 18. DRINKING WATER. - (1) In every factory effective arrangements shall be made to provide and maintain at suitable points conveniently situated for all workers employed therein a sufficient supply of wholesome drinking water. (2) All such points shall be legibly marked "drinking water" in a language understood by a majority of the workers employed in the factory, and no such point shall be situated within six meters of any washing place, urinal, latrine, spittoon, open drain carrying salvage or effluent or any other source of contamination unless a shorter distance is approved in writing by the Chief Inspector. (3) In every factory wherein more than two hundred and fifty workers are ordinarily employed, provisions shall be made for cooling drinking water during hot weather by effective means and for distribution thereof. (4) In respect of all factories or any class or description of factories the State Government may make rules for securing compliance with the provisions of sub-sections (1), (2) and (3) and for the examination by prescribed authorities of the supply and distribution of drinking water in factories. 24
  • 25. 19. LATRINES AND URINALS. - (1) In every factory - (a) sufficient latrine and urinal accommodation of prescribed types shall be provided conveniently situated and accessible to workers at all times while they are at the factory; (b) Separate enclosed accommodation shall be provided for male and female workers; (c) Such accommodation shall be adequately lighted and ventilated, and no latrine or urinal shall, unless specially exempted in writing by the Chief Inspector, communicate with any workroom except through an intervening open space or ventilated passage; (d) All such accommodation shall be maintained in a clean and sanitary condition at all times; (e) Sweepers shall be employed whose primary duty it would be to keep clean latrines, urinals and washing places. (2) In every factory wherein more than two hundred and fifty workers are ordinarily employed - (a) all latrine and urinal accommodation shall be of prescribed sanitary types; (b) the floors and internal walls, up to a height of ninety centimeters, of the latrines and urinals and the sanitary blocks shall be laid in glazed titles or otherwise finished to provide a smooth polished impervious surface; (c) without prejudice to the provisions of clauses (d) and (e) of sub-section (1), the floors, portions of the walls and blocks so laid or finished and the sanitary pans of latrines and urinals shall be thoroughly washed and cleaned at least once in every seven days with suitable detergents or disinfectants or with both. (3) The State Government may prescribe the number of latrines and urinals to be provided in any factory in proportion to the numbers of male and female workers ordinarily employed therein, and provide for such further matters in respect of sanitation in factories, including the obligation of workers in this regard, as it considers necessary in the interest of the health of the workers employed therein. 25
  • 26. 20. SPITTOONS. – (1) In every factory there shall be provided a sufficient number of spittoons in convenient places and they shall be maintained in a clean and hygienic condition. (2) The State Government may make rules prescribing the type and the number of spittoons to be provided and their location in any factory and provide for such further matters relating to their maintenance in a clean and hygienic condition. (3) No person shall spit within the premises of a factory except in the spittoons provided for the purpose and a notice containing this provision and the penalty for its violation shall be prominently displayed at suitable places in the premises. (4) Whoever spits in contravention of sub-section (3) shall be punishable with fine not exceeding five rupees. Safety Culture An organization with a "safety culture" is one that gives appropriate priority to safety and realizes that safety has to be managed like other areas of the business. For the shipping industry, it is in the professionalism of seafarers that the safety culture must take root. That culture is more than merely avoiding accidents or even reducing the number of accidents, although these are likely to be the most apparent measures of success. In terms of shipboard operations, it is to do the right thing at the right time in response to normal and emergency situations. The quality and effectiveness of that training will play a significant part in determining the attitude and performance - the professionalism - the seafarer will subsequently demonstrate in his, or her, work. And the attitude adopted will, in turn, be shaped to a large degree by the 'culture' of the shipping company. 26
  • 27. The key to achieving that safety culture is in: • recognizing that accidents are preventable through following correct procedures and established best practice; • constantly thinking safety; and • Seeking continuous improvement. It is relatively unusual for new types of accidents to occur on board and many of those that continue to occur are due to unsafe acts by seafarers. These errors, or more often violations of good practice or established rules, can be readily avoided. Those who make them are often well aware of the errors of their ways. They may have taken short- cuts they should not have taken. Most will have received training aimed at preventing them but, through a culture that is tolerant to the 'calculated risk', they still occur. The challenge for trainers and training, and managers ashore and afloat, is how to minimize these unsafe acts, how to instill not only the skills but also the attitudes necessary to ensure safety objectives are met. The aim should be to inspire seafarers towards firm and effective self-regulation and to encourage personal ownership of established best practice. Internationally recognized safety principles and the safeguards of best industry practice have to become an integral part of an individual' own standards. Hazards, risks, outcomes The terminology used in OSH varies between states, but generally speaking: • A hazard is something that can cause harm if not controlled. • The outcome is the harm that results from an uncontrolled hazard. • A risk is a combination of the probability that a particular outcome will occur and the severity of the harm involved. 27
  • 28. “Hazard”, “risk”, and “outcome” are used in other fields to describe e.g. environmental damage, or damage to equipment. However, in the context of OSH, “harm” generally describes the direct or indirect degradation, temporary or permanent, of the physical, mental, or social well-being of workers. For example, repetitively carrying out manual handling of heavy objects is a hazard. The outcome could be a musculoskeletal disorder (MSD) or an acute back or joint injury. The risk can be expressed numerically (e.g. a 0.5 or 50/50 chance of the outcome occurring during a year), in relative terms (e.g. "high/medium/low"), or with a multi-dimensional classification scheme (e.g. situation- specific risks). Hazard Assessment Hazard analysis or hazard assessment is a process in which individual hazards of the workplace are identified, assessed and controlled/eliminated as close to source (location of the hazard) as reasonable and possible. As technology, resources, social expectation or regulatory requirements change, hazard analysis focuses controls more closely toward the source of the hazard. Thus hazard control is a dynamic program of prevention. Hazard-based programs also have the advantage of not assigning or implying there are "acceptable risks" in the workplace. A hazard-based program may not be able to eliminate all risks, but neither does it accept "satisfactory" -- but still risky—outcomes. And as those who calculate and manage the risk are usually managers while those exposed to the risks are a different group, workers, a hazard-based approach can by- pass conflict inherent in a risk-based approach. Risk assessment Modern occupational safety and health legislation usually demands that a risk assessment be carried out prior to making an intervention. It should be kept in mind that risk management requires risk to be managed to a level which is as low as is reasonably practical. 28
  • 29. This assessment should: • Identify the hazards • Identify all affected by the hazard and how • Evaluate the risk • Identify and prioritize appropriate control measures The calculation of risk is based on the likelihood or probability of the harm being realized and the severity of the consequences. This can be expressed mathematically as a quantitative assessment (by assigning low, medium and high likelihood and severity with integers and multiplying them to obtain a risk factor, or qualitatively as a description of the circumstances by which the harm could arise. The assessment should be recorded and reviewed periodically and whenever there is a significant change to work practices. The assessment should include practical recommendations to control the risk. Once recommended controls are implemented, the risk should be re-calculated to determine of it has been lowered to an acceptable level. Generally speaking, newly introduced controls should lower risk by one level, i.e, from high to medium or from medium to low. 1.9 RESEARCH METHODOLOGY Methodology is a systematic way to solve the research problem. It may be understand as a science of studying how research is done logically. The various steps that are generally adopted by a researcher problem are also the main function of the research methodology. RESEARCH DESIGN Descriptive research studies are concerned with describing the characteristics of a particular individual or of a group, or a situation. This type of 29
  • 30. research design can be used in conditions where decision problem are linked to answer specific question concerning who, what when, and how a topic. In the study the researcher wants to elevate “how” effective the performance appraisal system are using a structured Questionnaire for collection of data, hence the research design used is descriptive in nature. DATA COLLECTION The two types of data used for the purpose and study are Primary data & Secondary data, 1. Primary data It relates to the study was collected from the operators level in the company. It was collected through interview and questionnaire method. The other methods such as observation, indirect oral interview and detailed discussion with the employees had been conducted for the purpose of data collection. 2. Secondary data Secondary data are those which have already been collected by some other agency and which have already been processed. Secondary data for the study has been complied from the reports and official publication of the organization, which have helped in getting and insight of the present scenario existing in the operation of the company. Sampling plan Sampling is the selection of some part of an aggregate or totality on the basic of which a judgment or inference about the aggregate or totality is made. Sampling technique A population is the collection of elements about which one has to make some inference. The population was 100 the researcher followed censes sampling method, which is the count of all elements, in a population. 30
  • 31. RESEARCH METHODOLOGY Key issue Options selected Data source Primary and secondary data Research approach instrument Interview survey questionnaire Contact method Personal contact. QUESTIONNAIRE DESIGN The questionnaire used for collecting the data is a structured one. It was a mixture of open ended, closed ended and multiple industry choices. The words used were simple and help in avoiding confusion and misunderstanding among the respondents. During questions were avoided in order to make sure that the questions were arranged in a logical order and So that the respondent would not find the questions confusing. Sampling Procedure KEY ISSUES OPTION SELECTED Sample Unit Operators Sample Size 100 31
  • 32. SAMPLING PROCEDURE The first step of research design is used to formulate the objective of research plan, which while specify the way of achieving research objectives questionnaires were used to collect the needed information. The sampling method was conveniences sampling and it is made in such a view freely with hesitation. SAMPLING UNIT • The operators were surveyed SAMPLE SIZE • 100 samples of operators considered for the study. SURVEY METHOD The survey method used by the researcher was self- administered survey. Self – administered survey is data collection technique in which the respondent read the survey question and records his /her answer without the presence of a trained interviewer. STATISTICAL TOOLS 1. Simple Percentage Percentage refers to a special kind of ration .Percentage are used in making comparisons between two or more series of data. Percentage is used to describe relationships. Percentage can also be used to compare the relative terms the distribution of two or more or more series of data. 2. Chi-Square Analysis Chi square test is a non-parametric test. Marking researches to test hypotheses uses it most frequently. The test is employed for testing hypotheses when distribution if population is not know and when nominal data in to be analyzed. The quantity x2 describes the magnitude of discrepancy between theory and observation. Verity the distribution of observed data with answered theoretical 32
  • 33. distribution non parametric test. The symbol “X2” is the Greek letter Chi. the Test was first used by Kara person in the year 1990.  The Quantity χ2 is defined as χ2 = (Oi-Ei/Ei) 2 Where, Oi = Refers to the observed frequency Ei = Refers to expected frequency 33
  • 34. CHAPTER II 2.1 DATA ANALYSIS AND INTERPRETATION 1.1.1 PERCENTAGE ANALYSIS TABLE: 2.1.1 DISTRIBUTION OF THE RESPONDENTS- AGE WISE No. of S. No Particulars respondents Percentage 1 Up to 20 0 0 2 21-30 10 10 3 31-40 20 20 4 41-50 50 50 5 Above50 20 20 Total 100 100 CHART: 2.1.1 DISTRIBUTION OF THE RESPONDENTS- AGE WISE INFERENCE: It is found from the above table that 10% of the respondents between 21-30 years of age level, 20% of the respondents between 31-40 years of age level, 50% of the respondents between 41-40 years of age level, 20% of the respondents belongs to above 50 years of age level and none of the respondents are below 20 years of age, 34
  • 35. TABLE: 2.1.2 DISTRIBUTION OF THE RESPONDENTS- DESIGNATION WISE No. of S. No Particulars Respondents Percentage 1 Operator 65 65 2 Fitter 15 15 3 Welder 10 10 4 Burner 4 4 5 Painter 6 6 Total 100 100 CHART: 2.1.2 DISTRIBUTION OF THE RESPONDENTS- DESIGNATION WISE INFERENCE: 65% of the respondents are operator, 15% of the respondents are fitter, 10% of the respondents are welder, 4% of the respondents are burner and 6% of the respondents are painter. 35
  • 36. TABLE: 2.1.3 DISTRIBUTION OF THE RESPONDENTS- DEPARTMENT WISE No. of S. No Particulars respondents Percentage 1 Loader Assembly 40 40 2 Axle Plant 15 15 3 Dumber FABN 30 30 4 Tool Room 5 5 5 FOP Paint 10 10 Total 100 100 CHART: 2.1.3 DISTRIBUTION OF THE RESPONDENTS- DEPARTMENT WISE INFERENCE: It is found from the above table 40% of the respondents are loader assemble, 15% of the respondents are axle plant, 30% of the respondents are dumber FABN, 5% of the respondents are tool room and 10% of the respondents are FOP paint. 36
  • 37. TABLE: 2.1.4 DISTRIBUTION OF THE RESPONDENTS- MARTIAL STATUS No. Of S. No Particulars respondents Percentage 1 Single 18 18 2 Married 82 82 Total 100 100 CHART: 2.1.4 DISTRIBUTION OF THE RESPONDENTS- MARTIAL STATUS INFERENCE: It is found from the above tables 18% of the respondents are single and 82% of the respondents are married. 37
  • 38. TABLE: 2.1.5 DISTRIBUTION OF THE RESPONDENTS- QUALIFICATION WISE No. of S. No Particulars respondents Percentage th 1 10 30 30 2 12th 34 34 3 Diploma 16 16 4 PG 2 2 5 Others 18 18 Total 100 100 CHART: 2.1.5 DISTRIBUTION OF THE RESPONDENTS- QUALIFICATION WISE INFERENCE: It is inferred from the above table that 30% of the respondents have qualified in 10th, 34% of the respondents have qualified in 12th, 16% of the respondents have qualified in diploma, 2% of the respondents have in PG level and 18% of the respondents have qualified in others. 38
  • 39. TABLE: 2.1.6 DISTRIBUTION OF THE RESPONDENTS- EXPERIENCE WISE No. Of S. No Particulars respondents Percentage 1 Up to 5 yrs 6 6 2 6-10 Yrs 9 9 3 11-15 Yrs 11 11 4 16-20 Yrs 15 15 5 >20 Yrs 59 59 Total 100 100 CHART: 2.1.6 DISTRIBUTION OF THE RESPONDENTS- EXPERIENCE WISE INFERENCE: It is inferred from the above table 6% of the respondent belongs up to 5 years’ experience level, 9% of the respondents between 6-10 years experience level, 11% of the respondents between 11-15 years, 15% of the respondents between 16-10 years level and 59% of the respondents above 20 years experience level. 39
  • 40. TABLE: 2.1.7 AWARE OF THE SAFETY SYSTEM No. Of S. No Particulars respondents Percentage 1 Yes 100 100 2 No 0 0 Total 100 100 CHART: 2.1.7 AWARE OF THE SAFETY SYSTEM INFERENCE: 100% of the respondents are aware of the safety system prevailing in factory. 40
  • 41. TABLE: 2.1.8 WORK PERMIT SYSTEM No. Of S. No Particulars respondents Percentage 1 Yes 52 52 2 No 48 48 Total 100 100 CHART: 2.1.8 WORK PERMIT SYSTEM INFERENCE: 58% of the respondents are satisfied with their work permit systems and 42% of the respondents are unsatisfied with their work permit systems. 41
  • 42. TABLE: 2.1.9 SAFETY IN TOOL BOX MEETING No. Of S. No Particulars respondents Percentage 1 Yes 90 90 2 No 10 10 Total 100 100 CHART: 2.1.9 SAFETY TOOL BOX MEETING INFERENCE: 90% of the respondents have agreed with their tool box meeting and 10% of the respondents have disagreed with their tool box meeting. 42
  • 43. TABLE: 2.1.10 CONTROL MEASURE TO ENSURE SAFETY No. Of S. No Particulars respondents Percentage 1 Yes 86 86 2 No 14 14 Total 100 100 CHART: 2.1.10 CONTROL MEASURE TO ENSURE SAFETY INFERENCE: It is inferred from the above table 86% of the respondents have agreed with their proper control systems and 14% of the respondents have disagreed with their proper control systems. 43
  • 44. TABLE: 2.1.11 IMPORTANCE OF SAFETY IS COMMUNICATED TO THE EMPLOYEES No. Of S. No Particulars respondents Percentage Observance of the safety 1 weeks 76 76 2 Safety competitions 78 78 3 Talks on safety 82 82 Booklet in 4 Boards/Slogans 69 69 5 Booklets 14 14 6 House Magazines 14 14 7 Visual Displays 33 33 Total 100 100 CHART: 2.1.11 IMPORTANCE OF SAFETY IS COMMUNICATED TO THE EMPLOYEES INFERENCE: 76% they agree with safety weeks, 78% they agree with safety competitions, 82% they agree with talks on safety, 69% they agree with bullet in boards, and each 14% they agree with booklets, house magazines and 33% they agree with visual displays. TABLE: 2.1.12 REDUCE THE RISK OF HAVING ACCIDENTS 44
  • 45. No. Of S. No Particulars respondents Percentage 1 Strongly agree 7 7 2 Agree 82 82 3 Disagree 5 5 4 Strongly Disagree 6 6 Total 100 100 CHART: 2.1.12 REDUCE THE RISK OF HAVING ACCIDENTS INFERENCE: It is inferred from the above table that 7% of the respondents have strongly agreed with their reduce the accidents, 82% of the respondents have agree, 5% of the respondents have disagree and 6% of the respondents have strongly disagree. TABLE: 2.1.13 ASSES THE RISK RATING IN WORK 45
  • 46. No. of S. No Particulars responsibility Percentage 1 Strongly agree 6 6 2 Agree 81 81 3 Disagree 9 9 4 Strongly disagree 4 4 Total 100 100 CHART: 2.1.13 ASSES THE RISK RATING IN WORK INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their asses the risk rating in work , 81% of the respondents have agree, 9% of the respondents have disagree and 4% of the respondents have strongly disagree. 46
  • 47. TABLE: 2.1.14 ADEQUATE NUMBER OF TRAINING PROGRAMS No. Of S. No Particulars responsibility Percentage 1 Strongly agree 6 6 2 Agree 77 77 3 Disagree 13 13 4 Strongly disagree 4 4 Total 100 100 CHART: 2.1.14 ADEQUATE NUMBER OF TRAINING PROGRAMS INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their adequate number of training programs on safety , 77% of the respondents have agree, 13% of the respondents have disagree and 4% of the respondents have strongly disagree. 47
  • 48. TABLE: 2.1.15 PROGRAMS CONDUCTED ON SAFETY No. Of S. No Particulars responsibility Percentage 1 Strongly agree 6 6 2 Agree 76 76 3 Disagree 14 14 4 Strongly disagree 4 4 Total 100 100 CHART: 2.1.15 PROGRAMS CONDUCTED ON SAFETY INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their programs conducted on safety, 76% of the respondents have agree, 14% of the respondents have disagree and 4% of the respondents have strongly disagree. 48
  • 49. TABLE: 2.1.16 TRAINING NEEDS IDENTIFIED FOR THE EMLOYEES No. of S. No Particulars responsibility Percentage 1 Strongly agree 6 6 2 Agree 83 83 3 Disagree 8 8 4 Strongly disagree 3 3 Total 100 100 CHART: 2.1.16 TRAINING NEEDS IDENTIFIED FOR THE EMLOYEES INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their training needs, 83% of the respondents have agree, 8% of the respondents have disagree and 3% of the respondents have strongly disagree. 49
  • 50. TABLE: 2.1.17 SAFETY RULES, INSTRUCTIONS HAVE BEEN DISPLAYED No. of S. No Particulars responsibility Percentage 1 Strongly agree 6 6 2 Agree 80 80 3 Disagree 9 9 4 Strongly disagree 5 5 Total 100 100 CHART: 2.1.17 SAFETY RULES, INSTRUCTIONS HAVE BEEN DISPLAYED INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their safety rules, instructions have been displayed, 80% of the respondents have agree, 9% of the respondents have disagree and 5% of the respondents have strongly disagree. 50
  • 51. TABLE: 2.1.18 LAY OUT OF WORK PLACE No. of S. No Particulars responsibility Percentage 1 Strongly agree 6 6 2 Agree 83 83 3 Disagree 8 8 Strongly 4 disagree 3 3 Total 100 100 CHART: 2.1.18 LAY OUT OF WORK PLACE INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their layout of work place have been properly designed to avoid the accidents, , 83% of the respondents have agree, 8% of the respondents have disagree and 3% of the respondents have strongly disagree. 51
  • 52. TABLE: 2.1.19a INTEGRATED SAFETY SYSTEM No. of S. No Particulars respondents Percentage 1 Yes 35 35 2 No 65 65 Total 100 100 CHART: 2.1.19a INTEGRATED SAFETY SYSTEM INFERENCE: 35% of the respondents have agreed with their integrated safety system and 65% of the respondents have disagreed with their integrated safety system. 52
  • 53. TABLE: 2.1.19b ADHERENCE TO THE SYSTEM IS GOOD No. of S. No Particulars responsibility Percentage 1 Strongly agree 5 14 2 Agree 20 57 3 Disagree 6 17 4 Strongly disagree 4 11 Total 35 100 CHART: 2.1.19b ADHERENCE TO THE SYSTEM IS GOOD INFERENCE: It is inferred from the above table that 14% of the respondents have strongly agreed with their adherence system, 57% of the respondents have agree, 17% of the respondents have disagree and 11% of the respondents have strongly disagree. TABLE: 2.1.20a FIRST AID BOXES ARE AVAILABLE 53
  • 54. No. Of S. No Particulars respondents Percentage 1 Yes 31 31 2 No 69 69 Total 100 100 CHART: 2.1.20a FIRST AID BOXES ARE AVAILABLE INFERENCE: 31% of the respondents have agreed with their first aid boxes are available at the work place and 69% of the respondents have disagreed. TABLE: 2.1.20b ADEQUATE MEDICINES AVAILABLE 54
  • 55. No. of S. No Particulars responsibility Percentage 1 Strongly agree 4 13 2 Agree 10 32 3 Disagree 13 42 4 Strongly disagree 4 13 Total 31 100 CHART: 2.1.20b ADEQUATE MEDICINES AVAILABLE INFERENCE: It is inferred from the above table that 13% of the respondents have strongly agreed with their adequate medicines are available in work place, 32% of the respondents have agree, 42% of the respondents have disagree and 13% of the respondents have strongly disagree. TABLE: 2.1.21 LIGHTING FACILITIES PROVIDED TO THE WORKPLACE 55
  • 56. No. of S. No Particulars responsibility Percentage 1 Strongly agree 6 6 2 Agree 85 85 3 Disagree 5 5 4 Strongly disagree 4 4 Total 100 100 CHART: 2.1.21 LIGHTING FACILITIES PROVIDED TO THE WORKPLACE INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their adequate lighting facilities provided to the work place, 85% of the respondents have agree, 5% of the respondents have disagree and 4% of the respondents have strongly disagree. TABLE: 2.1.22 SAFETY VALVES HAVE BEEN PROVIDED 56
  • 57. No. of S. No Particulars responsibility Percentage 1 Strongly agree 7 7 2 Agree 84 84 3 Disagree 5 5 4 Strongly disagree 4 4 Total 100 100 TABLE: 2.1.22 SAFETY VALVES HAVE BEEN PROVIDED INFERENCE: It is inferred from the above table that 7% of the respondents have strongly agreed with their safety valves provided at the pressure vessels, 84% of the respondents have agree, 5% of the respondents have disagree and 4% of the respondents have strongly disagree. TABLE: 2.1.23 NOISE LEVEL MONITORED 57
  • 58. No. of S. No Particulars respondents Percentage 1 Strongly agree 6 6 2 Agree 24 24 3 Disagree 64 64 4 Strongly disagree 6 6 Total 100 100 CHART: 2.1.23 NOISE LEVEL MONITORED INFERENCE: It is inferred from the above table that 6% of the respondents have strongly agreed with their noise level is regularly monitored and controlled at the work place, 24% of the respondents have agree, 64% of the respondents have disagree and 6% of the respondents have strongly disagree. TABLE: 2.1.24 FULL FLEDGED MEDICAL CENTRE S. No Particulars No. of Percentage 58
  • 59. respondents 1 Strongly agree 4 4 2 Agree 25 25 3 Disagree 65 65 4 Strongly disagree 6 6 Total 100 100 TABLE: 2.1.24 FULL FLEDGED MEDICAL CENTRE INFERENCE: It is inferred from the above table that 4% of the respondents have strongly agreed with their full fledged medical centre, 25% of the respondents have agree, 65% of the respondents have disagree and 6% of the respondents have strongly disagree. TABLE: 2.1.25 ALL ACCIDENTS AND NEAR-MISSES ARE FORMALLY INVESTIGATED 59
  • 60. No. of S. No Particulars respondents Percentage 1 Strongly agree 9 9 2 Agree 91 91 3 Disagree 0 0 4 Strongly disagree 0 0 Total 100 100 CHART: 2.1.25 ALL ACCIDENTS AND NEAR-MISSES ARE FORMALLY INVESTIGATED INFERENCE: It is inferred from the above table that 9% of the respondents have strongly agreed with their accidents and near-misses are formally investigated, 91% of the respondents have agree, 0% of the respondents have disagree and 6% of the respondents have strongly disagree. TABLE: 2.1.26 OPENION ABOUT SAFETY FACILITIES ARE PORVIDED S. No Particulars No. of Percentage 60
  • 61. respondents 1 Highly satisfied 7 7 2 Satisfied 86 86 3 Dissatisfied 5 5 4 Highly Dissatisfied 2 2 Total 100 100 CHART: 2.1.26 OPENION ABOUT SAFETY FACILITIES ARE PORVIDED INFERENCE: It is inferred from the above table that 7% of the respondents are highly satisfied with their safety measures provided by the company, , 86% of the respondents have agree, 5% of the respondents have disagree and 2% of the respondents have strongly disagree. 2.2.1 CHI-SQUARE TEST 61
  • 62. TABLE 2.2.1 AGE AND FIRST AID BOXES Null Hypothesis (H0) : There is no significant relationship between age and first aid boxes. Alternative Hypothesis (H1) : There is a significant relationship between age and first aid boxes. Age and Up to 20 21-30 31-40 41-50 >50 Total First Aid Boxes Strongly 0 2 0 1 3 6 Agree Agree 0 3 5 8 9 25 Disagree 0 2 7 39 17 65 Strongly 0 1 0 2 1 4 Disagree Total 0 8 12 50 30 100 Observed Expected (Oi-Ei)2/Ei Frequency(Oi) Frequency(Ei) 0 0 0 2 0.48 4.8 0 0.72 0.72 62
  • 63. 1 3 1.3 3 1.8 0.8 0 0 0 3 2 0.5 5 3 1.3 8 12.5 1.62 9 7.5 0.83 0 0 0 2 5.2 1.97 7 7.8 0.08 39 32.5 1.3 17 19.5 0.32 0 0 0 1 0.32 1.4 0 0.48 0.48 2 2 0 1 1.2 0.03 CHI - SQUARE TEST The formula for Ψ2 = Σ (Oi-Ei) 2 / Ei Calculated χ2 value = 17.45 Degree of Freedom = (R-1) (C-1) = (4-1) (5-1) = 12 Table value χ2 = 21.03 Result = Calculated χ2 value 17.45 < Table value χ2 21.03 at 5% level of significant. 63
  • 64. INFERENCE It is found from the above table that calculated value is less than the table value at 12 degree of freedom. Hence, Null hypothesis (H 0) accepted. It concluded that there is no significant relationship between age and first aid boxes. TABLE 2.2.2 EXPERIENCE AND NOISE LEVEL Null Hypothesis (H0) : There is no significant relationship between experience and noise level. Alternative Hypothesis (H1) : There is a significant relationship between experience and noise level. Experience Up to 5 6-10 Yrs 11-15 Yrs 16-20 Yrs >20 Yrs Total and Noise Yrs Level 64
  • 65. Strongly 1 1 0 0 2 4 Agree Agree 3 3 4 8 10 28 Disagree 1 5 6 7 46 65 Strongly 1 0 1 0 1 3 Disagree Total 6 9 11 15 59 100 Observed Expected (Oi-Ei)2/Ei Frequency(Oi) Frequency(Ei) 1 0.24 2.41 1 0.36 1.14 0 0.44 0.44 0 0.6 0.6 2 2.36 0.5 3 1.68 1.04 3 2.52 0.09 4 3.08 0.27 8 4.2 3.44 10 16.5 2.57 1 3.9 2.16 5 5.85 0.12 6 7.2 0.18 7 9.8 0.78 46 38.4 1.53 1 0.18 3.74 65
  • 66. 0 0.27 0.27 1 0.33 1.36 0 0.45 0.45 1 1.77 0.34 CHI - SQUARE TEST The formula for Ψ2 = Σ (Oi-Ei) 2 / Ei Calculated χ2 value = 23.43 Degree of Freedom = (R-1) (C-1) = (4-1) (5-1) = 12 Table value χ2 = 21.03 Result = Calculated χ2 value 23.43 > Table value χ2 21.03 at 5% level of significant. INFERENCE It is found from the above table that calculated value is greater than the table value at 12 degree of freedom. Hence, Null hypothesis (H 0) rejected. It concluded that there is significant relationship between experience and noise level. 66
  • 67. TABLE 2.2.3 TRAINING AND SATISFACTION Null Hypothesis (H0) : There is no significant relationship between training and satisfaction. Alternative Hypothesis (H1) : There is a significant relationship between training and satisfaction. Experience Up to 5 6-10 Yrs 11-15 Yrs 16-20 Yrs >20 Yrs Total and Noise Yrs Level Strongly 1 1 0 0 2 4 Agree Agree 3 3 4 8 10 28 Disagree 1 5 6 7 46 65 Strongly 1 0 1 0 1 3 Disagree 67
  • 68. Total 6 9 11 15 59 100 Observed Expected (Oi-Ei)2/Ei Frequency(Oi) Frequency(Ei) 1 0.24 2.41 1 0.36 1.14 0 0.44 0.44 0 0.6 0.6 2 2.36 0.5 3 1.68 1.04 3 2.52 0.09 4 3.08 0.27 8 4.2 3.44 10 16.5 2.57 1 3.9 2.16 5 5.85 0.12 6 7.2 0.18 7 9.8 0.78 46 38.4 1.53 1 0.18 3.74 0 0.27 0.27 1 0.33 1.36 0 0.45 0.45 1 1.77 0.34 CHI - SQUARE TEST 68
  • 69. The formula for Ψ2 = Σ (Oi-Ei) 2 / Ei Calculated χ2 value = 23.43 Degree of Freedom = (R-1) (C-1) = (4-1) (5-1) = 12 Table value χ2 = 21.03 Result = Calculated χ2 value 23.43 > Table value χ2 21.03 at 5% level of significant. INFERENCE It is found from the above table that calculated value is greater than the table value at 12 degree of freedom. Hence, Null hypothesis (H 0) rejected. It concluded that there is significant relationship between experience and noise level. CHAPTER III 69
  • 70. 3.1 SUMMARY OF FINDINGS This chapter deals with the main findings which are mainly drawn from the previous chapter (Analysis and Interpretations). These main findings are very important for this study to come out with the appropriate suggestions. The followings are main findings drawn from the study. MAIN FINDINGS • Majority(50%) of the respondents working in Caterpillar age between 41-50 • Majority (65%) of the respondents are operator. • Majority (40%) of the respondents are under come loader assembly department. • More than three fourth of the employees (82%) were married. • 100% of the respondents working in Caterpillar were male. • Majority of the respondents (34%) educational status were +2. • Majority of employees (59%) had served at caterpillar for more than twenty years. • 100% of the respondents are aware of safety system prevailing n the factory • Nearly half of the employees (52%) have been provided with work permit systems in their factory • Majority of the respondents (90%) are provided with priority for safety in Tool box meeting. • 86% of the respondents say that they have been provided with proper control measure to ensure safety in their work place. • Nearly half of the employees (82%) of respondents the importance of safety is communicated through talks on safety. • Nearly three fourth (82%) of the employees agree that safety measures will reduce the Risk of having accidents. • Nearly half of the respondents (81%) accepted that there is a system in a place to asses the risk rating in their day to day work. • 77% of the respondents feel that they have been given adequate number of training programs in Caterpillar. 70
  • 71. Three fourth of the respondents (76%) say’s that the programs conducted on safety is very effective. • Majority of the respondents (83%) think that the training programs as per identified training needs. • 80% of the respondents agree that safety rules, instructions have been displayed everywhere in the factory permanently. • Nearly three fourth (83%) of the employees accepted that the layout of the work place have been properly designed to avoid accidents. • 65% of the employees feel that there is no integrated safety systems provided in machines and they suggested that company can adhere to a system which is good. • More than half of the respondent (69%) says that there is adequate number of first aid boxes available in the factory. • 85% of the respondents are agreed with their lighting facilities provided to the employees at work place. • More than half of the respondents agree that the safety valves have been provided with pressure vessels. • Nearly three fourth of the employees strongly disagree that the noise level is regularly monitored and controlled in the factory. • Nearly three fourth of the employees (65%) feels that the company do not have the full fledged first aid provision. • Majority of the employees (91%) agree that all accidents and all near misses are formally investigated. • 86% of the respondents are satisfied with the overall safety provisions provided in the factory. 3.2 SUGGESTIONS 71
  • 72. Adequate number of first aid boxes should be provides in every department and also provides an adequate number of medicines in the work place. • The companies try to provide different way of awareness programs on safety. • Full fledged first aid centre should be improved and maintained. • Noise level should be control and monitor regularly. • Safety valves should be providing to pressure vessels. • Electric circuit and electric wires should be checked, maintained properly. • The integrated safety system of the machines should be improved. • Work permit system to be implemented. • Company should asses the equipments used by every employees. 72
  • 73. 3.3 CONCLUSION A study was conducted on the safety management system at CIPL. A majority of 86% of the respondents were found to be satisfied with the safety measures at CIPL, 7% were highly satisfied, and only 5% were dissatisfied , 2% of them highly dissatisfied. Most of the employees feel company should improve their first aid centre and adequate medicines are easily available in all work place Employees also feel noise level should be monitored and controlled. The company should be given improved work permit system to employees. 73
  • 74. BIBLIOGRAPHY BOOKS: • Industrial Safety - J. Nagaraj and V.Ramachandra Rao • Industrial Relations -ArunMonapa • Human Resource and Personnel Management Fourth Edition, Tata Mc Graw Hill Publishing -K. Aswathappa • Organization Behaviour - L.M. Prasad • Personnel Management - Dr. Gupta websites http://en.wikipedia.org/wiki/Safety_culture http://www.theiplgroup.com/safety culture-review http://safetyatworkblog.wordpress.com 74
  • 75. APPENDIX “A STUDY ON SAFETY MANAGEMENT SYSTEMS WITH REFERENCE TO CATERPILLAR INDIA PRIVATE LIMITED” QUESTIONNAIRE Personal Details Age : [ ] up to 20 [ ] 21-30 [ ] 31-40 [ ] 41-50 [ ]>50 Designation : Department : Martial Status : [ ] Single [ ] Married Gender : [ ] male [ ] female Educational Level : [ ] 10th [ ] 12th [ ] Diploma [ ] UG [ ] PG [ ] Others Length of Service : [ ] up to 5 Yrs [ ] 6-10 Yrs [ ] 11-15 Yrs [ ] 11-15 Yrs [ ] >20 Yrs 1. Are you aware of the safety system prevailing in your factory? [ ] Yes [ ] No 2. Do you have any work permit systems in your factory? [ ] Yes [ ] No 3. Is there any priority for safety in Tool Box Meeting? 75
  • 76. [ ] Yes [ ] No 4. Is there any proper control measure to ensure safety at your work place? [ ] Yes [ ] No 5. How the importance of safety is communicated to the employees? Please tick the appropriate answer. • Observance of the safety weeks • Safety competitions • Talks on Safety • Bullet in Boards/Slogans • Pamphlets • Booklets • House Magazines • Visual Displays 6. A safety measures reduce the risk of having accidents in your work place. [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 7. There is a system/method in place to asses the risk rating in your day to day work. [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 8. Adequate number of training programs on safety is conducted for the employees of caterpillar. 76
  • 77. [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 9. The programs conducted on safety are very effective. [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 10. Training programs are conducted as per training needs identified for the employees [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 11. A safety rules, instructions have been displayed everywhere in the factory permanently [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 12. The layouts of the workplace have been properly designed to avoid accidents. [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 13. Has any integrated safety system been provided in the machines? [ ] Yes [ ] No If yes, adherence to the systems is good [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 14. Adequate numbers of first Aid boxes are available at the work place. [ ] Yes [ ] No If yes, adequate numbers of medicines are available [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 15. Adequate lighting facilities have been provided at the workplace. 77
  • 78. [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 16. Safety valves have been provided at the pressure vessels? [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 17. Company have a full-fledged medical centre [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 18. Noise level is regularly monitored and controlled at the work place [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 19. All accidents and all near-misses are formally investigated [ ] Agree [ ] Strongly Agree [ ] Disagree [ ] Strongly Disagree 20. Are you satisfied with the safety measures provided by your company? [ ] Highly Satisfied [ ] Satisfied [ ] Dissatisfied [ ] Highly Dissatisfied 78