TRL Krosaki

Safety is the top priority for our company. We believe that our organization can run without accidents and we commit to create it a "Safe Place to Work". It is our firm conviction that all causes of accidents are manmade and can be resolved by men. Our commitment to zero accident has manifested in a number of preventive measures, guidelines, awareness campaigns, training programmes and improvement initiatives.

One such initiative taken was launching of Safety Excellence Journey (SEJ) with the guidance of TATA Steel, a role model on safety practices imbibed from world renowned DuPont practices. The Journey, which was rolled out on 14th March 2012, has introduced a number of Safety Standards, safety procedures & practices and a set of committees with specific responsibilities to ensure the implementation.

The Company observes National Safety Week & Safety Month (March), National Road Safety Week & Road Safety Month (January), National Fire Services Day, etc. to promote safety awareness amongst the employees including the contract workers. The company ensures Annual Health Checkup of all its employees and contract workers.

TRL Krosaki has received several awards and accolades on safety and occupational health care at national & state level.

  • Safety is line manager's responsibility.
  • All injuries are preventable.
  • Felt concern and care for employees' health & safety round the clock.
  • Working safely is condition of employment.
  • Safety training is essential to improve competency to work safely.
  • Recognizing hazards, fixing of required Engineering & Administrative control measures is the direction towards maintaining a safe workplace.
  • Adherence to Risk assessment, Standard Operating Procedure (SOPs), checklist, work permit and use of required PPEs prevents accident.
  • Personal Protective Equipment is the last layer of control measure.
  • Rewarding for remarkable contribution on safety and reprimanding violations will improves safety culture.

Managing Director - Occupier of the factory declares the Safety & Health Policy statement. The senior management of TRL Krosaki Refractories Limited demonstrates leadership and commitment through active participation in safety and by setting personal example & action. Sr. Management participates in Safety meetings, conduct safety observations to identify & rectify at-risk behaviours on the part of the workers and to encourage a positive attitude towards Safety.

Line Walk by Top & Sr. Management: Apex Safety Council members including the Chairman of the committee - the Management Director walk down on regular basis to various shops. All the Sr. Leaders of the company also go for line walk to the shop floor regularly. They aim to understand the safety & health issues at the shop floor and immediately intervene to rectify the same.

It helps in implementing the safety management decisions. Employees give lot of suggestions and ideas because they are the people ultimately working in the field and understand the issues better than anybody else. Their involvement in the discussion making process motivate to take own safety of self, colleagues and the work environment. We have established various platforms for participation & involvement of employees.

Employees Participation in Safety Management:

A Apex Safety Council (ASC) Objective: - To give directions and formulate Company's overall safety Policy and review implementation effectiveness. ASC is being chaired by MD & meeting frequency is at least once in a quarter.
B ASSC (Training & Communication) Objective:- To develop design & impart training programmes and communications related to SHE. This committee is being chaired by VP (Corporate Services) & meeting frequency is at least once in every two months.
C ASSC (Safety Standards) Objective:- To develop documents on safety standards on different critical / key processes & activities. This committee is being chaired by Sr. GM (Maintenance) & meeting frequency is at least once in every two months.
D ASSC (Cont. Mgt., Rail, Road, Logistics) Objective:- To formulate procedure, guidelines etc. in the areas of Contractor Management and Road & Rail logistics. This committee is being chaired by VP (Supply Chain Management) & meeting frequency is at least once in every two months.
E ASSC (Incident Invest. & Audit, Obs.) Objective:- To formulate plan, guidelines, procedure for understanding incident investigation and making safety audit & observations. This committee is being chaired by VP (Production) & meeting frequency is at least once in every two months.
F Plant Safety Implementation Committee (PSIC) Objective:- To implement policies, procedures, guidelines related to SHE & ensure compliance including statutory requirements. To identify and mitigate risks. This meeting is conducted once in a month and chaired by Sr. VP(O). This committee consists of equal number of workers representatives & management representatives. Safety issues are discussed in connection with accidents / incidents, housekeeping, unsafe conditions & acts, other survey status, medical check-ups, statutory compliances, any improvements. The minute is circulated to all the concerned personnel in the departments, for the execution & implementation of the decision of the safety committee within a stipulated time. This is again reviewed in the next meeting till the jobs are complied.
G Departmental Safety Committee (DSC) Objective: - To implement policies, procedures, guidelines related to SHE. To identify and mitigate process safety hazards / incidents / near miss etc. to comply with statutory requirements. This meeting is conducted once in every month at department level, which is chaired by respective HOD's involving shop floor level employees. Any unresolved points raised at department level are discussed in PSIC meeting & the issues are solved.
H Jt. Departmental Council (JDC) This meeting is conducted once in every month at department level, which is chaired by respective HOD's involving shop floor level employees. In this platform apart from safety & welfare, other issues related to productivity, CD activities, HR etc. are discussed. In this committee, participation of management & workers is 50:50.

TRL Krosaki Ltd. has created excellent training facilities for training and development of all its stakeholders.

J J Irani Centre for Learning: A state of the art Training Institute named J J Irani Centre for Learning has been considered as the Best Training Institute among all Refractories industries in India & in the state of Odisha. This institute has air conditioned class rooms equipped with all modern training gadgets like LCD, Computers, laptops, Flip Charts, etc.

The learning center organizes class room training, workshops, conferences, etc. on Technical , Managerial, Behavioural, Safety, Health and Environment programs for the employees, contract workers, contractors, customers and other stakeholders.

In addition to classroom training, shop floor awareness programs are organized by the Departments.

Orientation training is administered to all new employees prior to the initial work assignment. The orientation training includes all required safety & health information as well as job and site training.

Training modules are developed by competent professionals keeping in view of the activities, related hazards, incidents and statutory requirements. The orientation and subsequent training sessions includes, but not be limited to the following:

  • Induction safety training
  • Firefighting
  • Welding & gas cutting
  • Working at height
  • Working in confined space
  • Positive isolation
  • Emergency preparedness plan
  • First aid
  • Employees action in improving safety
  • Usage of PPEs
  • Health & life style management
  • Ergonomics
  • Electrical Safety
  • Road safety
  • Rescue operation
  • Workshop of HIRA
  • Dust hazard and preventive measures
  • Role of contractor supervisors
  • Role of contractors
  • Role of transporters
  • Crane safety
  • Safety in gas cylinder handling, etc.

We have made annual safety training calendar and training programs are conducted accordingly.

Note: No gate pass is issued to contract workers unless he has undergone safety induction training, medical checkup & HR clearances.

HIRA & CONTROL MEASURES:

Management is committed to identify hazards associated in all its activities, assess the risk and fix required control measures to reduce the risk level to as low as practically possible. All identified hazards will receive a timely response. When hazards cannot be eliminated, they will be effectively controlled by engineering, administrative procedures, work practices, personal protective equipment or any suitable combination of these measures.

Approach being adopted to control risk:

  • Elimination
  • Substitution
  • Engineering Control
  • Administrative Control
  • Behavioural Control
  • Personal Protective Equipment

Engineering controls include, but not be limited to the following:

  • Isolation of the hazard
  • Timely warning
  • Interlocks & guards.
  • Preventive maintenance and repair of machinery and equipment.

Administrative procedures include, but not be limited to the following:

  • Standard Operating & Maintenance Procedures
  • Checklist System
  • Written programs to establish administrative guidelines for safe work practices.
  • Careful planning and performance of each assigned job, duty, or task.
  • Reduction in duration of exposure to hazards.
  • Adherence to safety and health rules and procedures.
  • Life saving rues & consequence management.

Required personal protective equipment will be used as the last barrier to control hazards. Personal protective equipment issued to the employees. Employees are trained to use the PPEs.

Standard Operating Procedures (SOP) & Standard Maintenance Procedures (SMP) are prepared thru' HIRA for safe operation and maintenance. Work procedures, Do's / Don'ts are displayed at the workplace. Training on SOP & SMP is mandatory for the workers before deploying them in job. MSDS (Material Safety Data Sheet) is available for all hazardous substances & displayed at the site.

Permit to work system, positive energy isolation system (LOTO) are being followed. Hazardous jobs like hot work, working at height, confined space, gas line; electrical job, etc. are considered under the purview.

We have planned to identify and control hazards on regular basis. Audits & inspections are conducted to identify existing and potential hazards in the plant. Corrective & preventive actions are taken accordingly to mitigate those hazards. Reports are forwarded to management for appraisal & review.

Self-inspections covers the entire plant. Employees conduct constant informal inspections of their work areas. If any unsafe condition or unsafe act is identified, employees are expected to communicate to their immediate supervisors. Inspection checklists are developed for specific operation / activities. Employees are to maintain the checklist system. Management allocates adequate time and resources to perform the inspection. Shift In-charges review the inspection checklists and takes required corrective & preventive action.

Annual audit plan is prepared for the plant considering the critical activities, vital installations & machineries. External audit is conducted by expert agencies and compliance thereof is ensured.

Behaviour Observation by Trained Observers:

Employees are trained to observe at-risk behaviours of workers in their departments. They intervene to rectify at-risk behaviours immediately when it is observed. Observations made by the observers are reviewed in the Department Safety Committee meeting. All the officers are doing behavioural observation regularly to improve safe behavior of employees.

Reporting of Hazards by Employees:

Employees are trained to recognize hazards prevailing at the workplace, which can affect their health & safety. All employees are required to report hazards and unsafe conditions existing at the workplace and he/she will take initiative for immediate correction or to inform the right person to take corrective action.

Respective HODs review status of all reported hazards during their Departmental Safety Committee meeting.

On-site Emergency Plan has been developed for the factory addressing the credible accident scenarios, which has been approved by Dir. (Factories & Boilers) Govt. of Odisha. This contains the main following elements.

  • Inventory of hazardous substances
  • Most credible hazard scenario
  • Emergency command structure
  • Roles of key persons
  • Details of facilities available to combat emergencies
  • Assembly point & siren codes during emergencies
  • Contact numbers of key persons
  • Mutual aid partners
  • Emergency control room & facilities available, etc.

Emergency accident scenarios have been identified and mitigation measures fixed. We are conducting mock drills regularly to strengthen our emergency preparedness in presence of statutory authorities & representatives from nearby industries. Apart from this, we also conduct fire drills in selective areas inside plant to involve shop floor level employees to enhance their awareness & responsibilities at the time of emergencies.

All incidents such as near misses, first aid cases, reportable & dangerous occurrences are reported thru' specified formats. All incidents are investigated by a team of employees including workers & officers to find out the root cause. Remedial measures suggested by the team, which gets implemented within stipulated time period. All these incidents are discussed in different forums of safety meetings & shop floor safety talks. The purpose of investigation & implementation of findings are to prevent recurrence of similar incidents in the organization.

It plays a very vital role & important function of the management. Modalities adopted for safety communication are safety meetings, safety talks, mass meetings, display of posters & banners, distribution of booklets & leaflets, display of warning signs / SOPs / Do's & Don'ts, SMS thru' mobile, practical demonstration, training program, mass awareness program, e-mails, audio visual aids, safety theme of the month, etc.

In order to promote safety we organize various programs during National Road Safety Week & Road Safety Month - January, National Safety Week & Safety Month - March, Fire Service Day, World Environment Day, Chemical Disaster Prevention day, etc. Various competitions like slogans, posters, essay, quiz, elocution, toolbox talk, first aid, safe work procedure, etc. are conducted to improve awareness of employees, workers, contractors, transporters & the public.

Safety campaigns like Safe Place to Work, Safety Starts from Home, Safety Theme of the Month are being conducted to strengthen safety culture in the organization. Both regular & contract workers participate in the programs.

We are awarding the employees, workers, contractors for their safety performance at different forums like monthly mass meetings, Road Safety Month / Week, Safety Month / National Safety Week, etc. Employees are also being awarded for their suggestions for improving safety in our company.

Based on the safety performance we are having various schemes of awards such as

  • Safest Shop Award: Running shield with cash
  • Surakshit Karyasthala Award: Three model work places awarded with running shield & cash
  • Well down Award: Cash award for individual safety excellence
  • Best CSM Implementing Contractor: Cash award with shield
  • Surakshit Bandhu Award: Workers including contractor workers awarded with gifts.
  • Safety Kaizen: Cash award with appreciation letter
  • Safety Gift Coupons: Sr. Leaders of the company give Safety gift coupons to the workers performing the job safely during line walk.

Life Saving Rule & Consequence Management: We have established Life Saving Rules (8 cardinal rules & 14 supplementary rules) in the company which advocates zero tolerance policy. Violation of Life Saving Rules, safety and health policy, procedures or rules of the company may invite imposition of Consequence Management. This tool is to ensure enforcement of the safety rules and procedures established in the company. The reprimand system applies to all employees & contractors of this company.

Our relentless efforts in Occupational Health & Safety Management has been recognized at various national & state level forums. Some key rewards & recognitions are mentioned below:

2018:

  • NSCI Safety Award for 2018 [Srestha Surakhya Puraskar-Silver Trophy]
  • Kalinga Safety Gold Award
  • SHE Excellence Award by CII Eastern Zone FY18

2017:

  • 13th CII ESH Best Practices Award - 2017 (Odisha Chapter)
  • SHE Excellence Award by CII Eastern Zone
  • State Safety Award - Best Environment Management

2016:

  • 12th CII ESH Best Practices Award - 2016 (Odisha Chapter)
  • Safety Innovation Award - Institution of Engineers (India).
  • Mines Safety Award - 1st Prize in Overall Performance
  • Mines Safety Award - 1st in Safety Performance and Consciousness
  • Mines Safety Award - 1st in Health and Welfare
  • Mines Safety Award - 2nd in Training.

2015:

  • State Safety Award - Lowest weighted accident frequency rate
  • State Safety Award - Best Performance in SHE
  • State Safety Award - Shrama Award
  • Directorate General of mines safety award for "Best Performance in mines safety"

2014:

  • State Safety Award - 2014 for Best Occupational Health Care

2013:

  • Greentech Safety Gold Award-2013
  • Golden peacock award for the year 2013 on Occupational Health & safety

2012:

  • Golden peacock award for the year 2012 on Occupational Health & Safety

Before:

  • State Safety Award for "Best Occupational Health care 2009"
  • State Safety Award for "Best performance in Accident Prevention Safety Management and Communication systems 2008"
  • Greentech Safety Awards 2006 on Occupational Health & safety.
  • National Safety Award for outstanding performance in Industrial safety as Runner-up during the year 1998 in achieving lowest average Frequency rate.

In addition to the above rewards & recognitions, our persistent endeavor to improve Safety at the customer sites has been recognized by our esteemed customers like TATA Steel Jamshedpur, TATA Steel KPO, TATA Steel Bhusan, JSW Tornangalu, ESSAR Steel, NINL, Odisha.

Some Key Accolades:

  • NSCI Safety Award - 2018
  • Kalinga Safety Gold Award - 2018
  • CII SHE Excellence Award Eastern Zone FY18
  • State Safety Award 2017
  • Mines Safety Award
  • Safety Innovation Award 2016