INTERNSHI_REPORT_JOB_SAFETY_ANALYSIS_PANKAJ.pdf

M/s METSO OUTOTEC INDIA PVT LTD.
Plot No. 611-612, Opposite Vallabh Nagar, Odhav Road,
Odhav, Ahmedabad, Gujarat 382415
Project Report on
JOB SAFETY ANALYSIS
Prepared By
Name: Gothi Pankaj Kumar Devabhai
Registration No: 19204321048
POST DIPLOMA IN INDUSTRIAL SAFRTY
Year 2021-22

JOB SAFETY ANALYSIS | M/S METSO OUTOTEC LTD 2021-22
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Table of Contents
Index of Figures........................................................................................................................... 4
Index of Tables............................................................................................................................ 4
List of Abbreviations.................................................................................................................... 5
Definitions .................................................................................................................................. 5
1.1 Air set sand..............................................................................................................................5
1.2 Cold box sand ..........................................................................................................................5
1.3 Core .........................................................................................................................................5
1.4 Core box ..................................................................................................................................5
1.5 Cupola......................................................................................................................................5
1.6 Die casting (permanent mould) process.................................................................................5
1.7 Green sand ..............................................................................................................................6
1.8 Hot box process – drying the mould.......................................................................................6
1.9 Induction furnace....................................................................................................................6
1.10 Mould...................................................................................................................................6
1.11 Pattern.................................................................................................................................6
ACKNOWLEDGEMENT.................................................................................................................. 8
Executive Summary ..................................................................................................................... 9
1 Introduction of Metso Outotec (Metso Outotec Group, 2022)............................................. 11
1.1 Background Information about the industry ........................................................................11
1.2 Foundry Layout......................................................................................................................15
2 Occupational safety & Health Policy/HSC Policy ................................................................. 16
3 HSE Organizational Set up .................................................................................................. 17
4 Major Hazardous and Risk of industry ................................................................................ 18
4.1 Hazards and their Controlling Methods................................................................................18
4.1.1 Molten Metal Explosion.................................................................................................18
4.1.2 Heat stress .....................................................................................................................19
4.1.3 Burns ..............................................................................................................................21

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4.1.4 Light radiation................................................................................................................22
4.1.5 Hazardous chemicals .....................................................................................................23
4.1.6 Hazard information........................................................................................................23
4.1.7 Physical hazards.............................................................................................................24
5 Personal Code of conduct with OSH.................................................................................... 26
5.1 OSH Code of conduct for the own employees......................................................................26
5.2 OSH Code of conduct for the external service providers......................................................26
5.3 OSH Code of conduct for the visitors....................................................................................26
6 Occupational Health Surveillance....................................................................................... 27
6.1 Periodically health checks up................................................................................................27
6.2 Infrastructure health Surveillance.........................................................................................27
6.2.1 First aid kit......................................................................................................................27
6.2.2 Dispensary......................................................................................................................27
6.2.3 Ambulance .....................................................................................................................27
7 Reporting System on Hazard/Accidents.............................................................................. 28
8 Administrative Aspects ...................................................................................................... 29
9 Fire Control System............................................................................................................ 32
10 Housekeeping.................................................................................................................... 34
11 PPE Compliance ................................................................................................................. 35
12 OHS relevant statutory compliance (Pleaders, 2022) .......................................................... 36
12.1 Safety compliances for foundry workers...........................................................................36
13 Metso Outotec Foundry Best Practices............................................................................... 86
14 Study on Job Safety Analysis .............................................................................................. 39
14.1 Basic Information about the Job safety Analysis...............................................................39
14.2 Record Sheets of JSA in Metso Outotec............................................................................44
15 Bibliography .....................................................................................................................101

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Index of Figures
Figure 1 Foundry Layout ......................................................................................................................15
Figure 2 HSE Organizational Set up......................................................................................................17
Figure 3 Fire System Layout.................................................................................................................33
Index of Tables
Table 1 Fire Alarms & Sirens code .......................................................................................................32
Table 2 Specific provisions of the Factories Act, 1948 - Section 11 to 49 ...........................................37
Table 3 Risk Matrix...............................................................................................................................41

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List of Abbreviations
Abbreviations Full Form
HSE Health Safety and Environment
OSH Occupational Safety and Health
JSA Job Safety Analysis
PPE Personnel Protective Equipment
MSDC Material Safety Data Sheet
DISH Directorate of Industrial Safety and Health
WC Workmen compensation policy
SOP Standard/Safe Operating Procedure
PM Particulate Matter
VOC Volatile Organic Compounds
Definitions
1.1 Air set sand
Sand that is coated with a resin and a catalyst. When packed around a pattern, it sets in air to
form a rigid mould able to withstand the casting pressures of molten metal. Bench life usually
10–20 minutes after the removal of the pattern.
1.2 Cold box sand
Sand that is coated with a resin and a catalyst and formed into a mould or core, through
which a gas setting agent is passed to form a rigid shape.
1.3 Core
A sand shape which is inserted into a mould to form an additional profile, hollow or cavity in a
casting.
1.4 Core box
Tooling used to make a core.
1.5 Cupola
A refractory lined stack into which layers of metallurgical coke, steel scrap, cast iron scrap, pig
iron and limestone are charged. The coke is ignited and the furnace temperature raised by the
use of a forced air blast. This is a continuous furnace and melting will continue as long as raw
materials are charged into the top of the stack. It is only used for the melting of cast iron.
1.6 Die casting (permanent mould) process
A process using a cavity machined into a metal mould into which molten metal is formed.
These moulds are used many times over.

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1.7 Green sand
Sand, clay and water mixed together and rammed around a pattern; the clay forms a
sufficient bond for a mould to be formed. After casting this sand mixture is reconstituted by
the addition of moisture and can be reused as a moulding medium. =
1.8 Hot box process – drying the mould
A sand, resin and catalyst mixture which is blown into a heated corebox (approx. 180°
Celsius). The heat acts to set the resin mixture, giving a strong sand core.
1.9 Induction furnace
Cylindrical furnace using a water-cooled electrical induction coil to induce heat into a scrap
metal charge, increasing its temperature beyond melting point. Used for melting steel, iron
and copper based alloys.
1.10 Mould
A cavity of sand or metal into which molten metal is poured to form a casting.
1.11 Pattern
Tooling used to form a mould.

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MAHATMA GANDHI LABOUR INSTITUTE
AHMEDABAD
(Established by the Government of Gujarat)
This is to certify that Mr. Gothi Pankaj Kumar Devabhai with registration No 19204321048 is a
student of Post Diploma in Industrial Safety (PDIS) course from 2011-22 batch of our Institute. The
student was deputed to M/s METSO OUTOTEC INDIA PVT LTD, Plot No. 611-612, Opposite Vallabh
Nagar, Odhav Road, Odhav, Ahmedabad, Gujarat 382415 for the Project study. Accordingly he has
successfully completed the task and submitted a report on “JOB SAFETY ANALYSIS OF THE
COMPANY”.
Place : Ahmedabad
Shree K Nimbark Dr. Suman Vaishnav
Guide Course Coordinator

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ACKNOWLEDGEMENT
This report has been prepared for the internship that has been done at Metso Outotec India Pvt
Ltd. to study the practical aspect of the course and implementation of the theory in the real field
with the purpose of fulfilling the requirements of the course of Post Diploma in Industrial Safety
(PDIS). The aim of this internship is to be familiar with the practical aspect and uses of theoretical
knowledge and clarity clarify career goals, so we have successfully completed the internship and
compiled this report as the summary and the conclusion that have drawn from the internship
experience. Besides I would like to thank full to Dr. Suman Vaishnav (Course Coordinator) for giving
us such a wonderful opportunity for gaining Practical Knowledge from this Industrial Internship, I
am deeply indebted to Mr. K Nimbark who offered valuable advice and support as Project Guide.
This important mission could be made possible thanks to their inspirational help coupled with
immense additional support cum well-wishes from all other learned faculties, supporting staff of the
institute, class representative as well as fellow students and friends. I could make use of number of
books, journals and reference material from the institute library which helped a lot in preparing this
report.
I also feel exceptionally grateful to the following senior level engineers, officers and
departmental representatives from Safety who extended mentor roles in many ways.
We would like to express our sincere gratitude to our internship coordinators who have given their
valuable time and given us chance to learn something despite having their busy schedules and Mr.
Vipul Patel (Dy. Manager HSE) & Mr. Kanji Dodiya (Sr. Officer HSE) their great guidance for
internship. the time in Metso Outotec India Pvt Ltd was very audacious and supportive to our
career through which We have gained valuable work experience that will help makes a favorable
impression on us as prospective future employers.
With deep gratitude & regards,
Gothi Pankaj

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Executive Summary
General observation regarding the occupational and environmental hazards
Industry had manufactured the different kinds of spares of mining & aggregates. According to
observation in the industry regarding the hazard’s industrial manufacturing process is leading
to occupational hazards and may some environmental hazards like air pollutants, Particulate
matter, heat stress and high noise area
A very important hazard clearly is that of the heat radiating from the process itself, and the
severe injury that can result from spillages of molten metal.
However, the process generates substantial amounts of metal fumes. For example lead in gun
metal, and other alloys, can contribute substantially to the foundry working environment in a
very harmful way, especially if methods of control at source including local ventilation are not
adequate.
Occupational Hazards:
The manufacturing Process of the industry is leading to metal melting and the melted metals
is pouring in the moulds as per the requirements of the customer. The occupational hazards
are leading role because of the manpower is more required, To the minimize the hazards
industry has getting as possible automation in their manufacturing processes, however may
kinds of works are not possible with the automation and the man power is require.
Industry has installed cranes and lifts also use forth leap for the high weightlifting in the
industry. Also, industry has used the auto lifting system for the transfer the moulds and
observed adequate Tagging the status of crane spares.
Industry has labeled Safe working procedure and the hazard prevention techniques at the
workplace as per applicable, differential roles is given by the HSE department to the
production units personnel regarding the follow up the safety procedures, regular
maintenance, breakdown maintenance, using PPE’s, regular filling the records of the
equipment or may activity.
Environmental Hazards
According to the observation due to some kinds of manufacturing processes like Hammering,

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separating the cast from mold, grinding, sand recycling the air quality may contaminated
because of the dust and fumes concentration disposed in air, also highly noise generated.
HSE Department
HSE department had discuss in morning meeting on regular basis with the responsible
personnel of the department regarding to the safety point of view.
Safety officers was conducting the minimum 3 rounds of the plant for the monitoring workers
and hazards also he was report the hazards in the adopted online system Global tool. HSE
department also gives the responsibilities to all personnel to inform about the observed
hazards.
Safety officers also gives the safety training to all employees in the periodically, refreshing and
to the new employment’s workers.
Implemented the segregation of hazardous waste collection and also colour indication for the
different kinds of hazardous wastes.
Also, PPE’s Colour coding system implemented for the visitor, department wise. Industry had
implemented work permit system for height/cold/hot work the external vendors and services
providers.
Disaster management system implemented by HSE and also onsite emergency plan was
established.

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1 Introduction of Metso Outotec (Metso Outotec Group,
2022)
1.1 Background Information about the industry
Metso Outotec is a frontrunner in sustainable technologies, end-to-end solutions, and services for
the aggregates, minerals processing, metals refining, and recycling industries globally. (Metso
Outotec Group, 2022)
By improving our customers’ energy and water efficiency, increasing their productivity, and
reducing environmental risks with our process and product expertise, we are the partner for
positive change. Metso Outotec is committed to limiting global warming to 1.5 0C with Science-
based targets.
Source (Metso Outotec Group, 2022)

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The production of metal castings is a complex proves that has long been associated with worker
injuries and illnesses that are related to exposure to chemical and physical agents generated by or
used in the casting process. Foundry workers may be exposed to numerous health hazards,

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including fumes, dust, gases, heat, noise, vibration, and nonionizing radiation.
Chronic exposure to some of these hazards may result in irreversible respiratory diseases such as
silicosis, an increased risk of safety hazards that can result in injuries including musculoskeletal
strain, burns, eye damage, loss of limb, and death. The major categories of adverse diseases.
1. Malignant and nonmalignant respiratory diseases
2. Traumatic and ergonomic injuries due to falling or moving objects
3. Heat-induced hearing loss
4. Eye Injury
Published scientific data on occupational injuries and illnesses in foundry workers, working
conditions, and the engineering controls and work practices used in sand casting foundries are
reviewed have been developed for reducing the safety and health risks related to working in sand
casting foundries. Because of the diversity and complexity of the foundry industry, this document is
limited to those facilities that pour molten metal into sand molds. Although die, permanent mold,
investment, and other types of casting are not specifically addressed, many of the processes and
materials are similar to those used in sand casting; the recommendations in this document may
apply to those foundries as well. However, only those processes, materials, and work procedures
specific to sand casting are discussed.
The foundry operations that have been studied include:
1. Handling raw materials such as scrap metal and sand
2. Preparing sand
3. Making molds and cores
4. Reclaiming sand and other materials used in mold and core production
5. Melting and alloying metals
6. Pouring
7. Removing cores and shaking out castings

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8. Rough cleaning of castings including chipping, grinding, and cut off operations
9. Maintaining and repairing equipment used in core making, mold making, and melting,
pouring, and rough cleaning operations
10. Cleaning foundry areas in which molding, core making, melting, pouring and rough cleaning
of castings occur.

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1.2 Foundry Layout
Figure 1 Foundry Layout

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2 Occupational safety & Health Policy/HSC Policy

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3 HSE Organizational Set up
Figure 2 HSE Organizational Set up
Source: (leading ehs, 2022)

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4 Major Hazardous and Risk of industry
4.1 Hazards and their Controlling Methods
Below are the hazards associated with the foundry operation and their control measures
1. Molten Metal Explosion
2. Heat Stress
3. Burns
4. Hazardous Chemicals
5. Physical Hazards
6. Health hazards
7. Hazardous waste and the environment
4.1.1 Molten Metal Explosion
 Steam Explosion
Steam explosions are caused by introducing moisture into molten metal or by pouring
molten metal onto materials containing moisture. Sources of moisture include:
 containers holding liquids e.g. drink cans, aerosols or mobile phone batteries
 heavily oxidized or rusted materials, or rust on the surface of tools or equipment
 damp refractories or tools.
To minimize the risks so far as is reasonably practicable, a person conducting a business or
undertaking must identify potential sources of moisture that could come into contact with
molten metal and take steps to stop contact from occurring. For example, by ensuring:
 Delivered materials are free from moisture and stored in a dry place.
 Furnaces and refractories are preheated before use.
 Equipment and tools are free from rust, dry, and preheated before use.

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 Charges are dry and free from entrapped moisture before being added to molten metal.
 Bottles and containers holding liquid and sealed, or pressurized cans are not taken into
molten metal areas. If these items are needed for maintenance or use, they should be
stored, used, and disposed of elsewhere.
 Chemical explosions
Chemical explosions can occur by introducing reactive chemical substances to molten metal
directly or as a contaminant in charge material, causing gas pressure build-up within the
molten metal. Not every addition of a reactive substance is potentially explosive, for
example adding aluminum or ferrosilicon as a de-oxidant.
Explosions can result from accidentally mixing oxidizing substances, for example ammonium
or potassium nitrate or other oxidising salts, into smelters or crucibles containing molten
metal or aluminium. Explosions may also occur if other incorrect combinations of chemicals
are put into a furnace, for example, furan and acid.
Control measures include:
 banning personal butane cigarette lighters in molten metal areas
 using storage systems to ensure products not suitable for use with molten metal are
clearly labelled, secured against accidental use and stored outside molten metal areas
 storing paints, solvents and other combustible or flammable materials in designated areas
to avoid ignition and cross-contamination
 as the last step before adding anything to molten metal, confirming it is the correct
product and is safe for use in that particular melt.
4.1.2 Heat stress
Working in hot conditions can be hazardous to health. Effects range from discomfort or heat
rash to heat exhaustion or heat stroke which can cause permanent injury or death. Heat

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stress can occur without the worker being aware of how much they are affected until it is
almost too late. It affects concentration, perception and decision making, so heat stress can
also affect behavior and jjudgment
Other factors besides furnace heat contribute to the body overheating for example:
 job factors including strenuous work, sustained work and inadequate recovery time
 seasonal factors including high air temperature and relative humidity, or low air
movement
 fatigue
 excessive or unsafe clothing
 unsuitable personal protective equipment (PPE).
Workers in hot environments can acclimatize or adapt to the heat. Discomfort can reduce,
sweating becomes more effective, salt loss reduces and recovery rates can return to normal.
Acclimatization takes time and is lost when workers are away from the environment, for
example, if workers go on vacation. Workers who have been away for a week or more should
be given time to reacclimatize. Acclimatizing only provides partial protection. While
acclimatized workers are at less risk than un-acclimatized, they are still at risk.
 Eliminating unnecessary heat and water vapour sources.
 Shielding radiant emissions from plant and other hot surfaces.
 Installing spot coolers, blowers, fans or air-conditioning to relieve humidity and move the
air.
 Using de-humidifiers and other humidity reduction methods.
 Using ventilation to draw in cooler air, for example flues.
 Automating tasks where practicable.
 Supplying clean fresh water.
 Providing respite areas for workers, for example a cool room or heat refuge.

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 Developing a heat stress policy and procedures to prevent heat stress. The policy should
include:
o educating workers about the signs and symptoms of excessive heat exposure and
heat stroke and the acclimatisation process
o ensuring a ‘buddy system’ where each worker looks after the other
o providing for frequent short water breaks at regular intervals during the shift e.g. a
cup of water (250 ml) every 15–20 minutes
o pacing work to suit the conditions
o scheduling hot work in cooler parts of the day
o isolating hot work by distance from other workers
o rotating hot tasks between workers to minimise exposure time
o continuous monitoring for signs or symptoms of excessive heat exposure and heat
stroke
o contingency plans and treatment for affected workers.
 Providing task-specific PPE, for example water cooled clothing or heat reflective clothing.
Picture 1Heat Stress Label
4.1.3 Burns
Burns are a major source of injury in molten metal foundries and are generally caused by
touching hot surfaces, radiation or splashing molten metal.

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 separating workers not directly involved in casting operation from the casting area
 automating machinery to minimise risks associated with manual handling of casting
moulds and other equipment if practicable
 designing and controlling processes to prevent unexpected reactions occurring
 providing protective barriers to prevent exposure to heat and splashes when a safe
distance cannot be provided e.g. screens around the pouring station
 providing task-specific PPE in addition to other control measures
 providing dry PPE when working with molten or hot metal
It is important to apply first aid to burns in order to reduce the risk of infection.
Picture 2Burn Hazard Symbol
4.1.4 Light radiation
Eye disorders and skin burns may be caused by intense ultraviolet and infrared radiation
from molten metal in furnaces, particularly around pouring areas and in welding
operations.
 providing workers who are likely to be exposed with shielding and PPE e.g. filtered eye
protection
 signing work areas indicating eye protection is required where there is a radiation risk

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 telling workers of the risks associated with intense ultraviolet and infrared radiation
 protecting bystanders and people passing preferably by exclusion.
Picture 3Light Radiation Hazard Symbol
4.1.5 Hazardous chemicals
Foundry workers may be exposed to hazards and risks from a range of hazardous
chemicals. A list of hazardous chemicals workers often come across in foundries is
provided in Appendix A. These include fumes and dusts generated from foundry
processes.
There are two broad types of hazards associated with hazardous chemicals which may
present an immediate or long-term injury or illness to people.
4.1.6 Hazard information
Information on the hazards of hazardous chemicals used in foundries can be found on
the chemical’s label and its safety data sheet (SDS). The SDS is a key document provided
by the supplier of hazardous chemicals. It gives information on hazards and risks of

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hazardous chemicals as well as how people may be exposed and instructions on how to
use, store, handle and dispose of the chemical safely. You should always read the label
and SDS before using a chemical.
Examples of chemicals used in foundries for which labels and SDS should be available
include:
 cleaning chemicals
 resins or binding agents used in moulds
 catalysts or alloying ingredients
 gases in cylinders
 abrasive blasting materials.
 Examples of hazardous chemicals generated at a foundry include:
 wood dust generated during pattern making
 metal fumes from heated or molten metals
 carbon monoxide, lead, zinc and other metal oxide fumes during charging and melting
processes
 cadmium fumes from overheating
 chromium III (trivalent chromium) and chromium VI (hexavalent chromium) from melting,
pouring and grinding of stainless steel or chrome alloys.
4.1.7 Physical hazards
Physical hazards are properties of chemicals created from chemical reactions. They can
present a risk through incorrect handling or use and can often cause injury to people or
damage to property. Examples include chemicals which are flammable, corrosive,
explosive, or have oxidising properties.
One of the biggest potential hazards in foundries is from physical hazards posed by some
hazardous chemicals. Fires and explosions at foundries have caused deaths and
substantial property damage.

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 labelling hazardous chemicals correctly
 controlling ignition sources and not introducing hazardous chemicals presenting a fire risk
into an area where ignition sources exist e.g. in areas with molten metal
 providing SDS
 storing incompatible chemicals well apart
 locating placards on or near bulk stores of hazardous chemicals in accordance with
Schedule 13 of the WHS Regulations
 preparing an Emergency Plan
 preparing manifests where required in accordance with Schedule 12 of the WHS
Regulations

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5 Personal Code of conduct with OSH
5.1 OSH Code of conduct for the own employees
 Industry has provided the occupational health center and conduct the health check up when
new personnel are inducted into the industry
 Occupational safety and health training is given by the HSE officers when new personnel are
joined, also refreshing time, and periodically training given by HSE officers.
 HSE department has given the Safe Operating procedure to all workplace
 Employee was guided to use the appropriate PPE’s as per the suitable and decided by the
HSE
 Industry has provided the deduction of ESIC
 All the employees are aware about the risks probabilities due to the work activities
 Industry has given the mandatory rules and regulations about the daily basis work
 Management has guided and committed for the further development and the further action
implemented by the HSE department
5.2 OSH Code of conduct for the external service providers
 Industry has regulated the rules and regulations for the external services including
contractual labor providers, transportation, environmental services, equipment services etc
 Service provider must have workmen compensation policy
 Service provider must have proper and original identity of the contractual employees
 Service provider has conduct the work after the issued and risk assessed by the HSE
department
5.3 OSH Code of conduct for the visitors
 Visitors must have original identity
 Visitors shall wear the PPE’s as per applicable requirement
 Industry has given the responsibility to security to provide the required verification of visitor
 Industry has given the responsibility to give proper safety training or instruction to visitor as
per the applicable

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6 Occupational Health Surveillance
6.1 Periodically health checks up
 Industry has assessed the physical health checkup of the newly inducted employees
 Industry has provided the Occupational Health center for the employees
 Industry also conducting the safety training in frequential
 Industry had provided first aid kit at the point of workplace
 Industry has also required the other contractual employee’s health checkup and WC policy
from the service provider
6.2 Infrastructure health Surveillance
6.2.1 First aid kit
o Industry has provided adequate first aid kit at the workplace
o Antiseptics & Cleansers. ...
o Antibiotics. ...
o Adhesive Bandages. ...
o Gauze Rolls / Gauze Pads / Trauma Dressings. ...
o First Aid Tapes. ...
o Wraps & Bandages. ...
o First Aid Instruments - Scissors / Tweezers / Tongue Depressors. ...
o Gloves / PPE
6.2.2 Dispensary
o Industry has provided the occupational health center for the primary treatment
6.2.3 Ambulance
o Industry has hired cars for the emergency

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7 Reporting System on Hazard/Accidents
HSE department has use the Global tool for the reporting the accident, investigation, hazard
identification and compilation of data
All data was confidential and authorized security to operate and manipulate

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8 Administrative Aspects
 Industry has provided canteen for food facility, canteen building having air conditioning and
good ventilation system installed
 Industry has implemented good housekeeping and serve good food quality
 Industry has developed adequate roads in the industry premises
 Indicated the areas and mirror at the turns (refer Picture 14 Convex Mirror)
 Adequately maintained the quality of roads in the industry premises
 Industry has provided good and adequate parking area, also having proper lighting at the
parking area
 Management has also gets positive steps on regular basis for the minimizing the manpower
and reducing risk and hazards

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Security aspects for OSH functions

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9 Fire Control System
Industry has installed fire alarm & sirens system
Table 1 Fire Alarms & Sirens code

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Figure 3 Fire System Layout
Source: Metso Outotec

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10 Housekeeping
 Foundries are also very prone to hazards from noise which can result in industrial
deafness and from vibration (in the fettling process) which can lead to hand arm vibration
syndrome. Some of them suffer from poor standards of "housekeeping" with numerous trip
hazards etc.
 Typically housekeeping is not possible in all production area of foundry industry because of
continuous generation of dust and other residual particles. However, industry has
mentioned as possible level of housekeeping in continuous basis.
 Industry haven’t any records of housekeeping, according to the observation industry has
allotted to specified personnel with specified roles and responsibilities. Industry has using
tractors, leader tractors and other equipment to collect the separated sands and other large
amount of waste.
 Industry has provided good sanitary facility and cleaned on regular basis, provide adequate
spaces and safe working platform for the workers
 Industry has segregated and labialized the waste collection system. Also industry has
calculate the food waste per week and displayed in the canteen.
 Industry has mentioned good housekeeping culture through such a kinds of rules and
regulations, display, posters and awareness about the ergonomic hazards and how to handle
the waste.

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11 PPE Compliance
Industry has implemented practice of using PPE’s on mandatory basis
HSE officer has assess the compliance of PPE’s on day by day activities and plant round
HSE department has implemented and displayed the MSDS sheets regarding Safety work
procedures and control of hazards at the workplaces
Picture 4 safe work procedure sheet

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12 OHS relevant statutory compliance (Pleaders, 2022)
12.1 Safety compliances for foundry workers
Following are some key Safety statutes (with latest amendments) which are applicable to a factory
running foundry and casting operations:
 The Factories Act, 1948 with applicable state factory rules
 Petroleum Act, 1934 with applicable State Petroleum Rules.
 Explosives Act, 1884 with applicable state Explosives Rules.
 Gas Cylinder Rules, 1981
 Static & Mobile Pressure Vessels (Unfired) Rules, 1981
 Electricity Act, 2003/ Indian Electricity Rules, 1956
 Motor Vehicles Act, 1988 /Central Motor Vehicles Rules, 1989
 Acts and rules of related to social security, i.e. the Employees’ Provident Fund and
Miscellaneous Provisions Act, the Employees’ State Insurance Corporation Act, the
Employees’ Compensation Act and the Maternity Benefits Act etc.
 Any other rules, i.e. local laws and rules, Safety expectations applicable to them
Note: Several industrial safety and welfare laws i.e. The Factories Act, 1948, The Dock Workers
(Safety, Health and Welfare) Act, 1986, The Mines Act, 1952, The Building and Other Construction
Workers (Regulation of Employment and Conditions of Service) Act, 1996, The Contract Labour
(Regulation and Abolition) Act, 1970 etc. shall be amalgamated by The Labour Code on
Occupational Safety, Health and Working Conditions which is enrolled as Bill No. 186 of 2019 and
has been INTRODUCED IN LOK SABHA by Minister of State for Labour and Employment in July 2019.

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Table 2 Specific provisions of the Factories Act, 1948 - Section 11 to 49
Required Health
Measures
Required Safety Measures Required Welfare Measures
 Cleanliness
 Disposal of
waste and
effluents
 Adequate
Ventilation of
Heat, dust and
fumes
 Adequate
lighting
 Drinking water
 No
overcrowding
 Artificial
humidification
 Fencing of Machinery
 Safety during Work on near
machinery in motion – Only
trained person with tight clothing
shall be allowed
 Detailed Health and Safety Policy
to be established
 Pre-employment Health and
Medical examination by a
certified medical surgeon
including pulmonary function
tests and chest X-ray
 Employment of Safety Officer
1000 or more workers
 Young person (Apprentice)
should be forbidden to work on
dangerous machines
 Screens and suitable goggles to
be provided for protection of
eyes.
 First-Aid facilities to be provided.
First Aid box to be maintained
(contents of the box shall be
provided as per the prescribed
State Factories Rules)
 Adequate number of fire
extinguishers to be provided
 Maintenance of machines to be
done periodically along with
examination report i.e. Hoist and
lifts (Yearly) / Pressure plants
(Half Yearly)/ Lifting machines,
 Adequate drinking water facility,
Washing and lightening facilities,
adequate ventilation etc. to be
provided
 Re-examined by a Certifying
Medical Surgeon at the
frequency of at least once in
every twelve months and to keep
a record in the form of the
medical history of every worker
engaged in hazardous operations
 Rest Room to be provided –
more than 150 workers
 Employment of Welfare Officer –
500 or more workers
 Notice of appointment/change
of occupier should be filed in
prescribed Form number -Within
15 days of appointment/change
 Notice of appointment/change
of manager should be filed in a
prescribed form within 07 days
of appointment/change
 Facility of Crèche, If more than
30 women are employed
 Canteen – On employment of
more than 25

Page 38 of 101
Wire Ropes, Chain Pulley blocks
(Yearly) / Plant and Machinery
(Yearly) etc.
 Protection against dangerous
fumes, gases etc
 Safety of building and machinery
 Maintenance of building
Safety Measures related to
Hazardous Processes
 Constitution of Site Appraisal
Committee
 Compulsory disclosure of
information by occupier
 Specific responsibility of occupier
related to hazardous process
operations
 Emergency Preparedness
Standards
 Permissible limits of exposure of
chemical and toxic substances
 Workers participation in safety
management
 Right of workers to warn about
imminent danger

Page 39 of 101
13 Study on Job Safety Analysis
13.1 Basic Information about the Job Safety Analysis
JSA appears to have evolved from the scientific management practice of job analysis (JA). In
fact, the first safety author to use the term job safety analysis was writing about JA (Heinrich,
1931).
A job safety analysis (JSA) is a procedure which helps integrate accepted safety and health
principles and practices into a particular task or job operation. In a JSA, each basic step of the
job is to identify potential hazards and to recommend the safest way to do the job.
The JSA is also known under other names, like
 Job Hazard Analysis (JHA)
 Safe Job Analysis (SJA)
 Task Hazard Analysis (THA)
Utilities of JSA
JSA is applied to jobs where:
 Accidents or near-accidents have occurred.
 One or more of those involved in the job are not familiar with all hazards and/or how
to protect against these hazards.
 A new team of workers are working together.
 Safe execution of the work requires close cooperation and coordination between
several people.
 New equipment or new processes are being introduced.
 Activities known for the highest injury/illness rates.
 Activities or jobs with no room for error, as the slightest lapse could lead to a fatal
accident.
 New activities or modified activities having new procedures.
 Complex activities requiring written instructions.
 Any activity with the slightest potential of being fatal.
Aim of JSA
 identify and evaluate hazards

Page 40 of 101
 Are caused by changes in work procedures or personnel
 May have been overlooked during the design of the job procedures, machinery,
equipment, etc.
 to find a safe way of performing a specified function
13.2 Objective of JSA
Objective of this procedure is to have a task/job based risk assessment process in place that
identifies, evaluates and controls the risks associated with work activities, and as a result,
prevents those involved in the task or those potentially affected by the task, from being
harmed.
13.3 Scope of JSA
 When new / different people will be undertaking the job for which an SOP / SMP is available
 When a non-routine task is to be undertaken
 When Job to be executed under Permit-To-Work (PTW)
 When deviations, due to some specific reasons, are required for Standard Operating
procedure (SOP) / SMP (Standard Maintenance Procedure)
 Whenever a job with a Standard Operating procedure (SOP) / SMP (Standard Maintenance
Procedure) is being undertaken in circumstances where the conditions of the job are
changed with respect to the SOP/SMP. e.g. A welder working in his fabrication area will be
covered by a SOP with HIRA already carried out, however, if the welding is being done on the
site at a height or a confined space or in an area which may interfere with other jobs we
need to conduct a JSA and use this in conjunction with the HIRA (Hazard Identification Risk
Assessment) for the welding activity.
13.4 Job Safety Analysis (JSA) involves the following:
 Determining the scope of the job and listing the steps in the job.
 Identifying possible hazards in the job.
 Determining who and/or what is at potential risk
 Describing the recommended safe way to do the job in order to prevent incidents and
injuries.
 Anticipating what might go wrong and devising back-up controls.
 Identify and address hazards.
 Prevent incidents and injuries.
 Get organized to do the job right and more efficiently.
 Create procedures that can be used by everyone.

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 Get people in the habit of working safely.
13.5 Procedure of JOB SAFETY ANALYSIS
 The four steps of a job safety analysis
A Breakdown of the 4 Steps of a Job Safety Analysis (JSA)
13.5.1 Select the activity to be analyzed.
Determine the activities which require a Job safety analysis. Give preference to the
activities which pose the highest threat to the workers' life.
13.5.2 Break the job down into specific tasks.
The activities should be broken down into steps following a proper sequence. This is a
critical step as the data will be used for future analysis or risk aversion.
13.5.3 Determine the potential hazards and risk present in each task.
The potential hazards and risks of injury in and around the activities should be
identified. Risk matrix is a popular tool for determining the risks.
Table 3 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
Effects are Felt But not
critical
Serious impact to course of
action and Outcome Could result in Disaster
Likelihood
Improbable
Risk
Unlikely
to occur
Possible
Risk will
Likely
Occur
Probable
Risk Will
Occur

Page 42 of 101
13.5.4 Identify preventative controls and residual risk.
Delineate the safety measures for each risk and hazard. Conduct the risk assessment to
determine the residual risk and repeat all the steps once again. Eliminating a hazard is
the goal, but in case it cannot be eliminated, it should be contained. OSHA’s standards
and regulations should be referred for intricate details of a risk.
13.6 Observation of the worker performing the job
To determine the basic steps, ask the following:
what step starts the job?
what is the next basic step?
Instead of (or in addition to) observing the the job being performed, we may also use
Discussion method: Several staff who perform the job provide input on job steps and hazards
Recall and check method: Staff does his own JSA using recollection of the job
13.7 Hazard Identification in JSA
During the hazard identification, the JSA officer should ask questions like:
What can go wrong?
What are the consequences?
How can it happen?
May there be other contributing factors?
How likely is it that the hazard will occur?
What safety measures, if any, are currently in place?
Is the environment hazardous to safety or health?
Are there flammable, explosive, or electrical hazards?
13.8 Benefits of JSA
 Identifies actual and potential hazards related to a job, and helps determine how these
should be managed
 Giving individuals training in safe and efficient job protection ❑ Preparing for planned

Page 43 of 101
safety observations
 Interesting new worker on the job
 Giving pre-job instructions on irregular jobs
 Reviewing job procedures after accident occurs
 Studying jobs for possible improvements in job methods
 Identifying what safeguards need to be in place
 Supervisors learn about jobs they supervise
 Increases worker involvement in the safety process
 Worker participation in workplace safety
 Positive attitudes about safety
 Health and safety awareness amongst the entire team is created. The communication
among the supervisor and laborers gets better, and acceptance of safe work
procedures is promoted.
 Training improves the knowledge of safety requirements among the employees. Thus,
simultaneously training documentation is also done.
 The likelihood of injury is reduced. This can add to accident-free man-hours on the
sites. Companies often boast about the same with pride.
 The written operating procedures can serve as guidance for initial training or
infrequent activities. It sets a standard for observing safety measures on the site.
 Further, it helps in performing extensive investigations of accidents

Page 44 of 101
13.9 Record Sheets of JSA in Metso Outotec Ltd
Sheet No: 01
Jobs Safety Analysis
(JSA)
Date : 10/06/2022
Risk Metrix No: 0, 1 & 3
Job/Activity Name:
Melting High chrome and manganese scrap (raw material) in
induction furnace
No Of Worker Engaged: 7
Department/Group Name
Production
Bldg./Area Location(S):
Melting area
Other Information:
Description of Activity: Industry has using the manganese and high chrome scrap as a raw material, in the induction
furnace around 1400 to 16000
C metals are melted and poured in the moulds as per the requirement, may different kinds
of matel concentration balance required for the quality purposes.
Industry having 4 Nos of induction furnace, capacity of furnace is 2 nos of 4 ton, 1 nos of 3 ton and 1 nos of 2 ton. Industry
has use induction furnace as per required quantity and characteristics of raw material
Hazard probable activity
Weighing/lifting/transferring and handling of the raw material, also due to the higher temperature at the work place may
probability of heat stress.
Lifting tools: Forth Leap, crane, magnate
Required Personal Protective Equipment for Entire Job
safety glasses safety shoes chemical resistant gloves other ______Breathing
Mask____________ other____________________
chemical goggles hard hat welding gloves
face shield harness lanyard leather gloves other ___________________
other____________________
welding goggles hearing protection
Note: marked PPE’s used during the work

Page 45 of 101
Sr
No
Basic Steps Potential Hazards Controls
1. Raw Material transferring through
fork leap at the melting area
hitting a fellow worker, blocked
sight, lack of proper training on
the part of the forklift operator.
falling loads, and falls from the
forklift
Operator must have proper training in
periodically
Operator should follow the manual of
manufacturer and safe work
procedure
2 Weighing the raw material with the
crane
Chain may break due to Over
Loading
Mechanical failure
Lake of using PPE
Mismatch equipment using
Operator must use the appropriate
PPE
Safety training should give in
periodically
Worker shall apply the SOP and
manufacturers manual in their
particulate activity
Operator shall check preventive and
breakdown maintenance of the
equipment’s
Industry has provided remote
controlled
3
Adding Raw Material in induction
furnace through crane
(electromagnetic cranes)
Heat injury
Heat stress
Loading
Workers must use the appropriate
PPE’s
equipment’s
controlled crane
4 Analyzing the temperature of the
molten
Heat injury
Heat Stress
Eye injury
Physical hazards
Operator shall follow the SOP
Operator shall use appropriate PPE’s
controlled crane
5 Transferring molten metal in crucible
6 Crucible of furnace
Deaths
Property loses
crucible dia increasing
water
Air introduced in the surface of
crucible
Industry has check preventive, regular
and breakdown maintenance
All personnel shall answer about the
risk and their potential
Workers shall check and maintain the
quality of their workplace and
equipment

Page 46 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
1 2
Possible
Risk will
Likely
Occur
3, 4 5
Probable
Risk Will
Occur
Indicated steps number in the risk matrix
Opinion and Interpretation about the risk:
Industry has provided adequate safety measures, however some hazards have probable for the severity of
risks.
JSA Conducted By Mr. Pankaj Gothi
Reviewed By Mr. Kanji Dodiya
Approved by Mr. Vipul Patel

Page 47 of 101
Sheet No: 02
(JSA)
Date : 11/06/2022
Risk Metrix No: 0 & 2
Job/Activity Name:
Scrap Cutting – raw material scrap cutting according the size
required , also adding the hooks for the better handling during the
transfer
No Of Worker Engaged:
Production
Blog/Area Location(S):
-
Other Information:
Raw material cutting
safety glasses safety shoes chemical resistant gloves other
__________________ other____________________
face shield harness lanyard leather gloves other ___________________
other____________________
Description of Activity: Activities regarding the required for the size of scrap and handling and transporting the material to
production area the scrap was cuts as per the size required in the induction furnace, cutting of scrap is carried out through
gas cutting and installed hook and joints through welding
All scraps were lifted through crane (capacity 2 ton)

Page 48 of 101
Sr
No
1. Raw material is transferred by hydra
because of high weight
Chain break due to over loading
Mechanical failure
Hydra Operator must have adequate
PIC
Industry has provide the work permit
and check the requirement as per
scope of work
2
Gas cutting and welding
acetylene, LPG and other fuel
gases are highly flammable, and
form explosive mixtures with air
and oxygen.
exposures to metal fumes and to
ultraviolet (UV) radiation
burns, eye damage, electrical
shock, cuts, and crushed toes and
fingers.
Protect your entire body with fire
retardant clothing, shoes, and gloves.
Industry has provided adequate open
area for the gas cutting and
appropriate PPE’s for the same
Industry has regular basis
maintenance and monitoring of the
work
3
Hearing damages due to High
Noise
Eye damages
Heat injury
Electric shock
Accidents caused by welding and
other hot work can cause serious
bodily harm and could result in
death.
 Risk Metrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
1
Possible
Risk will
Likely
Occur
2
Probable
Risk Will
Occur

Page 49 of 101
Industry has provided all the appropriate PPE’s regarding the gas welding, operator shall protect entire body
with provided fire retardant clothing, shoes, and gloves etc.
Industry has provided fire extinguisher and the safety procedure and hazards prevention procedure at the
work place. However may hazard or incident may due to illenace of worker

Page 50 of 101
Sheet No: 03
(JSA)
Date : 12/06/2022
Job/Activity Name:
IMF Shake Out (Equipment make: JK)
Working Principle: Separating the sand and casting from moulds
Production
Shake Out
Other Information:
Used for only separating the high chrome caste
Description of Activity: Industry has using the IMF Shake Out equipment which is separate the sand and cast through high
vibration.
After the adequate knock time the moulds is transferred in the IMF shake out by the auto operated leap and for the
adjustment worker was use the crane (capacity 7.5 Tone)
After the vibration the separated sand is recycled by air pressured line will collect and transferred for recycling.
Separated casting is transfer by the crane at the storing platform and thereafter it will be transferred through fork leap
__________________ other____________________
face shield harness lanyard leather gloves safety goggles
other____________________

Page 51 of 101
Sr
No
1. Moulds transferring through auto
operated lift
Mechanical Failure
Industry has adopted the
computerized operating system,
therefor no manpower required for
the transferring, industry has regular,
breakdown and preventive
maintenance
2 Separating the casting and sand from
moulds through IMF shake out
High Noise able to losses hearing
ability
Particulate matter is introduced in
the air and breathing
Chromium particles have been
linked with cancer.
Heat injury due to the high temp
of sand/casting
Miss handling of crane
Operators must use the appropriate
PPE
Safety training has given by HSE in
periodically
equipment’s
controlled
3 Collecting the materials and casting
after the separation
Heat injury
Heat stress
Loading
PPE’s
equipment’s
controlled crane

Page 52 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
1
Possible
Risk will
Likely
Occur
3
Probable
Risk Will
Occur 2
Industry has provided adequate safety measures; however, some hazards have probable for the severity of
risks. Operator may compromise the safety measures were the working load or may wrong attitude

Page 53 of 101
Sheet No: 04
(JSA)
Date : 13/06/2022
Job/Activity Name:
Hammering: Manganese cast
No Of Worker Engaged: 5 -6
Production
Hammering
Other Information:
Used for only manganese caste
Description of Activity: Hammering through Power hammer machine
The poured moulds is opened after required knock time (time is depends on quality purposes approx. time is 12 to 48 h)
Moulds plates is opened through cranes (Capacity 7 ton)
Separate caste and sand from the moulds after remaining sands is removed through power hammer machine
For handling the cast hooks was installed through welding
Residual sand is collected and recycled
Caste is transferred through fork leap for heat treatment
__________________ other____________________
goggles hard hat welding gloves
Safety shoes

Page 54 of 101
Sr
No
1. Opening plate wise the moulds after
proper knocking time
Heat injury
Chain break of crane
Physical Hazards
Industry has adopted the
computerized operating system,
therefor no manpower required for
the transferring, industry has regular,
breakdown and preventive
maintenance
2 Separating the caste and sand from
the
High Noise able to losses hearing
ability
Particulate matter is introduced in
the air and breathing
Metals particles introduced in air
quality
Heat injury due to the high temp
of sand/casting
Miss handling of crane
PPE
periodically
equipment’s
controlled
3 Hammering the caste to removing the
sands
Heat injury
metabolic heat stress
Loading
High noise generated at the time
of hammering
Sand and metal particles are
speedily coming on the around the
area
Tools breaks of equipment’s
PPE’s like earmuff, mask, goggles,
safety helmet and shoes etc
equipment’s
controlled crane
operator
4 Cast transferring for further process –
heat treatment through fork leap
forklift
periodically
procedure

Page 55 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
4
Possible
Risk will
Likely
Occur
3 1
Probable
Risk Will
Occur 2
risks. Operator may compromise the safety measures where the appropriate knock time was not applied to
moulds cooling and the workers are open the moulds.
Operator must use the PPE’s during the hammering with out operator will lose their hearing ability, may
breathing diseases occur after long time
When opening the moulds workers must be distance from the moulds and crane it having probable for high
risk of physical hazards and heat injury, burns.

Page 56 of 101
Sheet No: 05
(JSA)
Date : 16/06/2022
Job/Activity Name:
Manual Hammering: High Chrome caste
Production
Hammering
Other Information:
Used for only high chrome caste
Description of Activity: Hammering through manual and blowing the air
The castes which is separated through the IMF Shake out its comes in the manual hammering
Because of its notable for further adjustment like welding or may repair the worst spares its was hammered manually
Frist the removed the sand from inner side of the caste manually, using manual operating tools for removing sand
There after residual sand is removed by air blowing
And if required many other joints, excluding parts of caste, supportive joints are removed through grinding ss
__________________ other____________________
Safety shoes

Page 57 of 101
Sr
No
1. Castes is transferring to the
hammering rea through fork leap
forklift
periodically
procedure
2 Separating the sand from the caste
manually
Heat injury due to the may higher
temp inside of caste
Dust introduced to inhalation
Other Physical Hazards due to
handling the caste
PPE
periodically
equipment’s
controlled crane
3 Air blowing to caste for cleaning the
sand
Higher dust introduced during the
air blowing
High noise generated
Other Physical Hazards due to
handling the caste
equipment’s
Check appropriate pressure before air
blowing
controlled crane
operator
4 Grinding to the surface smoothing and
cutting the caste
injury risk in the use of grinding
wheels is that the wheel may burst
during grinding. ...
Eye injuries. Dust, abrasives,
grains, and splinters are a common
hazard to the eyes in all dry-
grinding operations.
Fire.
Vibration.
High Noise
Particles comes during the
grinding
Never use the grinder without
wearing all the personal protective
equipment and clothing such as
goggles, helmets, masks, ear
protection, gloves, leather aprons etc.
Also ensure that the personal
protective equipment and tools are in
proper condition before using them

Page 58 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
2 1
Possible
Risk will
Likely
Occur
3 4
Probable
Risk Will
Occur
risks. Operator may compromise the safety measures where the appropriate grinding worker were the PPE’s
and worker must be trained and follow up SOP
Restrict area during the grinding and cutting

Page 59 of 101
Sheet No: 06
(JSA)
Date : 07/06/2022
Job/Activity Name:
Heat Treatment: Manganese castes
Production
Heat Treatment
Other Information:
Used for only manganese caste
Description of Activity: Heat Treatment is given for the increasing the strength of castes
After the separation of caste from the moulds and hammering castes was comes for the heat treatment
Casting is transferred through the fork leap and put in the furnace through crane ( capacity 1 tone)
Availability of heat treatment furnace – 6 NOS
Knocking in the furnace at least 24 h or as applicable with regards quality purposes
There after casting is knocking for cooling
Manganese caste in cooled through water and high chrome caste is cooled at ambient air temperature
Transfer for further process gouging
__________________ other____________________
Safety shoes

Page 60 of 101
Sr
No
1.
Castes is transferring from the
hammering area for heat treatment
through fork leap
forklift
periodically
procedure
2 Putting the castes in the furnace
through crane (1 Tone capacity)
Heat injury due to the may higher
temp inside of caste
Over loading by the crane
Lake of maintenance of furnace
and crane apparatus
Over heating to the casting
Mechanical failure
Heat injury
Heat stress
Fumes and dust inhalation
Physical hazards
PPE
periodically
equipment’s
controlled crane
3 Removing castes and cooling the
castes
Works in higher temperature
cause heat stress
Heat injury causes due to manual
helps at the time of handling
Heat and burns injury
Lake of proper load correctly
Physical hazards
equipment’s
Check appropriate pressure before air
blowing
controlled crane
Operator
Operator must follow the manuals of
manufacturer

Page 61 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
Possible
Risk will
Likely
Occur
1 3
Probable
Risk Will
Occur 2
risks. Operator and workers may compromise the safety measures where sometime they may require some
help manually and they didn’t were PPE’s and getting injury because the caste having high temperature or
may hot surface, therefore workers shall use the PPE’s as mandatory basis.

Page 62 of 101
Sheet No: 07
(JSA)
Date : 19/06/2022
Job/Activity Name:
Air- Arc Gouging
Production
Gouging
Other Information:
Used for manganese and high chrome caste
Description of Activity: Gouging is minimizing the further process of finishing the castes
Removing the extra material and other joints and some surface cleaning as per the required for finishing
For the gouging mainly two functional works was conducted welding and cutting
__________________ other____________________
Safety shoes

Page 63 of 101
Sr
No
1. Welding
Noise, dust, respiratory irritation,
metal fume fever, lung cancer, skin
cancer, damage to the nervous
system, asphyxiation, and other
health risks. Safety hazards
associated with these processes
include burns, eye damage,
electrical shock, cuts, injury to toes
and fingers. Fires and explosions
may also occur.
Industry has provided the restricted
area for the outside persons
Industry has also installed separate
platform
Industry has provided metal wall
around the area like confined space
Fire extinguisher is available at the
workplace
SOP and Hazard prevention (do/don’t)
posters are labeled at the workplace
Industry has provided adequate PPE ‘s
2 Grinding
injury risk in the use of grinding
wheels is that the wheel may burst
during grinding. ...
Eye injuries. Dust, abrasives,
grains, and splinters are a common
hazard to the eyes in all dry-
grinding operations.
Fire.
Vibration.
High Noise
Particles comes during the
grinding
Never use the grinder without
wearing all the personal protective
equipment and clothing such as
goggles, helmets, masks, ear
protection, gloves, leather aprons etc.
Also ensure that the personal
protective equipment and tools are in
proper condition before using them
3 Material Handled through crane
Over Loading may causes accident
Break the chain
Miss handling and operating the
crane
equipment’s
controlled crane
Operator shall refer manufacturer
manuals

Page 64 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
Possible
Risk will
Likely
Occur
3 1
Probable
Risk Will
Occur 2
risks. Operator may compromise the safety measures where the appropriate grinding and cutting worker
were the PPE’s and worker must be trained and follow up SOP
Restrict area during the grinding and welding

Page 65 of 101
Sheet No: 08
(JSA)
Date : 20/06/2022
Risk Metrix No: 0
Job/Activity Name:
Fast Loop: Molding area
No Of Worker Engaged: 3-4
Production
Fast Loop
Other Information:
Used for manganese and high chrome moulds
preparation
Description of Activity: Moulds are prepared by following raw material and processes
Using mainly two type of sand resin and catalyst sand and olivine sand as a first layer to protect the surface of dye
Installed core of casting as per the requirement and shied for the not entering the sand in the core
Sand is filled through IMF mixer (IMF mixer (20 tone/H) is auto balanced for the quality and quantity balance of the sand,
auto operating system
After the adding sand and knocking for approx. 45 minutes and separate the prepared moulds through vertical rounded oil
pressurized machine
Moulds is auto lifted for the heat treatment
__________________ other____________________
Safety shoes

Page 66 of 101
Sr
No
1. Installation of Core
Physical hazard due to installation
of core
Mixed chemicals able to injure
hand, eye
Inhalation of high dust
Mechanical failure
Industry has provided adequate PPE’s
Workers shall for the SOP
2 Filling sand in pattern (dies)
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
2
Possible
Risk will
Likely
Occur
1
Probable
Risk Will
Occur
risks. Operator may compromise the safety measures where the appropriate PPE’s does not wear.

Page 67 of 101
Sheet No: 09
(JSA)
Date : 20/06/2022
Risk Metrix No: 0
Job/Activity Name:
Core Shop
Production
Core Shop
Other Information:
Used for manganese and high chrome Cores
Description of Activity: Cores was prepared by following raw material and processes
Using mainly two type of sand resin and catalyst sand and olivine sand as a first layer to protect the surface of dye
Installed core of casting as per the requirement and shied for the not entering the sand in the core
Sand is filled through IMF mixer (IMF mixer (6 Tone/H) is auto balanced for the quality and quantity balance of the sand,
auto operating system
After the adding sand and knocking and manually removed by the worker from the dies
Finishing the residual surface smoothing by craft paper and giving proper shape , also use crane for lifting the core
Painting the cores – color coding for manganese use light blue color and for high chrome use yellow color, if color was
mixed with thinner then fire on the core and remove the thinner

Page 68 of 101
__________________ other____________________
face mask harness lanyard leather gloves safety goggles
Safety shoes
Sr
No
1.
Filling sand into the core dies as per
the required quality and quantity of
sand
Physical hazard due to installation
of core
Mixed chemicals able to injure
hand, eye
Inhalation of high dust
Mechanical failure
2 Removing core from
3 Smoothing surface of core by craft
paper
Inhalation, eye injury through dust
and Physical hazard during the
lifted core smoothing Industry has provided adequate PPE’s
Workers shall use PPE’s on mandatory
basis
4 Painting and fire on the core
Heat injury
Burns
Skin disease
Inhalation of dusts and fumes

Page 69 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
1 & 2
Possible
Risk will
Likely
Occur
3 & 4
Probable
Risk Will
Occur
risks. Operator may compromise the safety measures where the appropriate PPE’s does not wear.

Page 70 of 101
Sheet No: 10
(JSA)
Date : 21/06/2022
Job/Activity Name:
Fast Loop: Drying/painting/core setting/Heat treatment/closing
Production
Fast Loop
Other Information:
preparation
Description of Activity: Moulds are prepared by following process
After the moulds separating from the dies moulds transferred for drying in hot air oven – heat the moulds for 5 minutes by
automatic lifting
Thereafter moulds were cleaned and printing the moulds as per the coding system
If color is prepared in thinner than fire on the moulds for the removing of thinner
Thereafter moulds are auto lifted in the core setting area, industry has provided 5 ton lift for the core installation in the
moulds
After the installation core moulds are auto lifted for heat treatment of moulds in the moulds drying oven (2000
C)
Thereafter the check the quality of prepared moulds if any kinds of cracks or other quality tolerance observed than the
moulds are removed from the panel through the crane
After the assessed moulds are lifted to the closing area
In the closing area as per the design of the moulds, operator was close the layers of moulds through the crane (capacity 7.5
Tone)
After tan moulds is lifted through auto car life system moulds is goes for the pouring the melton

Page 71 of 101
safety glasses safety shoes chemical resistant gloves other _________________
other____________________
face mask harness lanyard leather gloves safety goggles
Safety shoes
Sr
No
1. Moulds Heat treatment for drying
after the separation from dies
No major hazards observed
May probability of mechanical
failure
Industry has installed the auto lifting
chain for fast loop panel and the
moulds is transferred through the
auto lifting no manpower needs to
transfer such a activities
2 Cleaning of moulds through the air
blowing and craft paper
Dust inhalation, over material
handling by the crane
Mechanical failure
Tools failure
Not proper installed hooks on the
material
Require eye hearing protection and
gloves are mandatory also other
protection
3 Painting & fire on the moulds
Heat injury
Burns
Skin disease
Inhalation of dusts and fumes Industry has provided adequate PPE’s
basis
Workers must follow the SOP
4 Core setting in the moulds
Crane apparatus failure
Physical hazards during installation
during manual help

Page 72 of 101
5 Heat treatment in moulds drying oven
Heat stress on surrounding
ambient
Mechanical failure
No major hazard observed
Industry has installed the auto lifting
chain for fast loop panel and the
moulds is transferred through the
auto lifting no manpower needs to
transfer such a activities
6 Core setting and cleaning the residual
dust
Crane apparatus failure
Physical hazards during installation
during manual help
basis
7 Quality check and removing the
rejected moulds
Disposal of rejected moulds
carried If not mentioned adequate
distance than probabilities of
physical hazards
Over loading by crane
Tools and apparatus failure
Heat & burn injury
Regular, preventive and breakdown
maintenance of equipment’s
HSE is implement Safety training in
periodically interval.
basis
Use as possible automation work do
not get help the manually
8 Closing the layers of moulds
9 Lifting for the auto car plate form by
the crane
Break the chain
crane
equipment’s
controlled crane
manuals
10 Moulds lifting by the autocar for
pouring or may waiting storage yard
No major hazards observed
May probability of mechanical
failure
Industry has installed the autocar
lifting system and operate with given
software no need of man power in
such a kinds of activities

Page 73 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
1, 5 & 10
Possible
Risk will
Likely
Occur
2 & 3 4, 6 & 9 7 & 8
Probable
Risk Will
Occur
risks. Operator may compromise the safety measures where the system failure and appropriate PPE’s does
not wear.
Industry has minimized and reduced as possible consumption of manpower and well mentioned system for
the fast loop panel
Industry has conduct preventive, regular and breakdown maintenance of the whole panel equipment’s and
apparatus and maintain the records for the same.
HSE department will conduct 3 time in day safety observation round.
All the workers guided and trained to work with safety on mandatory basis.

Page 74 of 101
Sheet No: 11
(JSA)
Date : 21/06/2022
Risk Metrix No: 03
Job/Activity Name:
Pouring area
Production
Pouring area
Other Information:
preparation
Description of Activity: Casting consists of pouring molten metal into a mold, where it solidifies into the shape of the
mold.
Melton is transferred in ladle and filled into the mould
It will be store for required cooling time at the ambient temperature.
__________________ other____________________
face shield harness lanyard gloves safety goggles
Safety shoes

Page 75 of 101
Sr
No
1. Lifting the Melton and transfer at the
pouring area
Temperature of the metal or hot
surface, Burns, cuts, crushing,
electrocution, other accidents,
metal fumes, radiation
eye protection, gloves, spats (covering
top of feet), and thick clothing
protecting all exposed skin on arms
and legs.
NO polyester or synthetic clothing.
Sand Floor in pouring area shall be
clear of all objects not involved in
pouring. Clamp or weight up molds
that require it.
Workers should be alert as severe
burn injury can result from spillage of
the molten metal.
2 Filling Melton in the moulds
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
Possible
Risk will
Likely
Occur
Probable
Risk Will
Occur 1 & 2
risks. Operator may compromise the safety measures where the appropriate PPE’s does not wear and when
workers are getting lightly of risk with wrong attitude.

Page 76 of 101
Sheet No: 12
(JSA)
Date : 23/06/2022
Job/Activity Name:
Finishing the caste
Production
Finishing area
Other Information:
Used for manganese caste only
Description of Activity: Casting of manganese finished through following steps
Casting was slightly may banded and it was re shaped through the hydraulic press machine
After that casting is lifted for the grinding for the smoothing the surface and finishing the surface
There after the cast was transferred for SPM machine for miscellaneous surface shaping
There after the cast is transferred for policing and painting to another unit of the industry.
safety glasses safety shoes chemical resistant gloves other ______________
other____________________
Safety shoes

Page 77 of 101
Sr
No
1. Hydraulic press machine
Oil leaks
Overheating
Loss of pressure
Lake of safety training
Lake of operating knowledge
Improper fitting at the time of
press
Lake of maintenance
Mechanical failure
and legs.
basis
2 Surface grinder
Spread of used oiled water mixer
may probable for skin injury
press
Lake of maintenance
Mechanical failure
and legs.
basis
Industry has restricted the space and
provided the safety lock system
3 SPM machine
Metal particles probable risk to
physical hazard
press
Lake of maintenance
Mechanical failure
4 Cast lifting & Handling
(crane capacity 7 ton)
Break the chain
crane
equipment’s
controlled crane
manuals

Page 78 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
2
Possible
Risk will
Likely
Occur
2 1 & 4
Probable
Risk Will
Occur
risks. Operator may compromise the safety measures where the appropriate PPE’s does not wear during the
work
Industry has implemented LOTO system, tagging and locking the equipment authorization key through.
Also industry was conduct breakdown, preventive maintenance on frequential basis

Page 79 of 101
Sheet No: 13
(JSA)
Date : 24/06/2022
Risk Metrix No: 0 &1
Job/Activity Name:
Finishing the caste
Production
Finishing area
Other Information:
Used for high chrome caste only
Description of Activity: Casting of manganese finished through following steps
Casting was transferred into CNC machine for the removing and finishing the cast
After that casting is lifted for the drilling for the required cutting round hole as requirement
There after the cast was transferred to Horizontal boring machine for finishing the surface and boring
There after the cast is transferred for policing and painting to another unit of the industry.
other____________________
Safety shoes

Page 80 of 101
Sr
No
1. Computer Numerical Control
(CNC) Machine
Slips and falls around machinery,
injuries from unstable equipment,
Entanglement and the ejection of
parts.
Oil leaks
Overheating
press
Lake of maintenance
Mechanical failure
and legs.
basis
2 Drill Machine
entanglement, contaminant
inhalation, burns from hot drill
bits, and eye injuries
press
Lake of maintenance
Mechanical failure
and legs.
basis
Industry has restricted the space and
provided the safety lock system
3 Horizontal Boring machine
Metal particles probable risk to
physical hazard
boring
Lake of maintenance
Mechanical failure
Electricity load
4 Cast lifting & Handling
(crane capacity 7 ton)
Break the chain
crane
equipment’s
controlled crane
manuals

Page 81 of 101
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical
Likelihood
Improbable
Risk
Unlikely
to occur
2
Possible
Risk will
Likely
Occur
2 1 & 4
Probable
Risk Will
Occur
risks. Operator may compromise the safety measures where the appropriate PPE’s does not wear during the
work
Industry has implemented LOTO system, tagging and locking the equipment authorization key through.
Also industry was conduct breakdown, preventive maintenance on frequential basis

Page 82 of 101
Sheet No: 13
(JSA)
Date : 24/06/2022
Risk Metrix No: 2
Job/Activity Name:
Hazardous waste room
Hazardous waste
Hazardous waste room
Other Information:
Used for hazardous waste storage
Description of Activity: Segregation finished through following steps
Characteristics of generated hazardous waste
1. Machine residual waste
2. Used oil
3. Oil contaminated cotton cloth/filters
4. Contaminated PPE’s: Plastic/paper
5. Asbestos sheets wastes
6. Cooling tower fine waste
7. Discarded containers
8. Glass wool
9. E-waste

Page 83 of 101
other____________________
ss face shield harness lanyard leather gloves safety goggles
Safety shoes
Sr
No
1. Segregation of waste
Skin diseases
Allergy due to contaminations
Contaminants in inhalation
Physical hazard during handling
waste
Radiation
and legs.
basis
 Risk Matrix
Severity
Impacts
0
Acceptable
1
Tolerable
2
Unacceptable
3
Intolerable
Little or No effect
critical

INTERNSHI_REPORT_JOB_SAFETY_ANALYSIS_PANKAJ.pdf

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