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Home >> Industrial Safety Tips

Industrial Safety Tips


  • Follow the departmental standard operating procedures and safety norms.
  • Inform all unsafe acts, unsafe conditions, accidents, dangerous occurrences. And near miss accidents to your seniors.
  • Ensure use of personal protective equipment as and when required and keep same in well-maintained condition.
  • Maintain good housekeeping in the department.


  • Use all electrical wires, cables & materials of proper capacity and proper insulation.
  • Don't overload the electrical circuit.
  • Use Moulded Case Circuit Breaker of proper capacity to avoid the machine.danger of overload or short circuit.
  • Use I.S.I. Marked or quality control certified electrical materials and appliances.
  • Use 3 pin plug top instead of open wire in the socket.
  • In case of fire due to short circuit, first, switch off Main. switch, Don't use water.
  • Use Earth Leakage Circuit Breaker to avoid accidents from earth Leakage current.
  • Safety shoes & safe tools while working on electrical live lines.
  • Use electrical appliances having the provision of earthing i.e. 3 pins plug.
  • Keep meter room neat, clean and ventilated.
  • Don't use temporary wires.
  • Use insulated wire for neutral & independent wire for earthing.
  • Use only plug in a socket,
  • Don't use wires and cables having joints.
  • Ensure test remarks before using.
  • Provide copper plate or rod earthing to electrical installations.


  • Hazard: Hazard is defined as source or situation with a potential for harm in terms of human injury or ill health, damage to property, workplace, environment or a combination of these,
  • Risk: Risk is defined as the combination of likelihood and consequence(s) of the specified hazardous event occurring.
  • The simple method to recognize hazard is to use the five common senses (sight, hearing, smell, touch, taste).
  • Sight: Some things can be easily seen as dangerous.
  • Heating: An odd noise can mean that something is wrong that could lead to danger.
  • Smell: Unusual smell like that of a chemical can mean there is a Leakage that can cause irritation, suffocation or another problem.
  • Touch / Feel: Unusual warmth in an office can mean that the air-conditioner is not functioning properly causing discomfort.
  • Taste: Food that is distasteful could mean that it is spoilt and may lead to food poisoning.


  • Think safety before commencing the activity.
  • Know and understand all the safety features and instructions of the machine before operating the machine.
  • Read all warnings and danger notices.
  • Know where the emergency stop button is located.
  • Switch Off machine completely before changing or adjusting any parts of the machine.
  • Does not attempt any maintenance work on the moving parts of the machines.
  • If any part of the machine is not functioning, inform the same to your departmental engineer immediately. Don't attempt to repair it if you are not trained.
  • Use proper tools to work on the machine. Never use bare hands.
  • Does not wear loose clothing when working on machines.
  • Use appropriate personal protective equipment when operating or working on the machine.
  • Read and understand the machine instruction manual before operating the machine.


  • Material safety data sheet reveals information about potential dangers that could lead to an accident. names of another hazardous substance I properties of the said chemicals. safety precaution, its effects on human and environments, ways to fight with dangers and tips on the first Aid requirements.
  • Everyone who works with chemical directly or indirectly must read the MSDS.
  • The MSDS must also be carried when transporting chemicals including waste.
  • The MSDS is available with the user department. The copy of same is available with Emergency Control Center (Gate House), Health. Safety & Environment Department for reference.


  • API Manufacturing department, solvent yard, Dangerous petroleum store, corrosive material store, switch-yard are defined as hazardous areas.
  • Following are the safety instruction for these areas.
  • Switch OFF the mobile phones before entering the area.
  • During handling of flammable liquids precautions to be taken to eliminate static electricity.
  • Select and use personal protective equipment.
  • Understand properties of chemicals and storage methods. Possibility of hazards due to intermixing (of Non- compatible chemicals)
  • Follow disposal methods and deactivation procedures.
  • Ensure Guarding and use earthing I bonding.
  • Ensure Fire hazards possibility, type of fire extinguishers available and its use.
  • Follow Safety Permit Systems.
  • Ensure correct label before use.
  • Obey warning and danger signs
  • All concerned persons must be trained on chemical handling and MSDS.
  • Use eyewash or shower with plenty of water when you come in contact with chemicals (for minimum 20 minutes).
  • No visitors I suppliers I vendors are allowed to enter this area without permission.


  • label all chemicals and reagent bottles clearly. Store them in appropriate places.
  • Volatile, combustible, flammable chemicals must be stored away from direct flame and another source of heat.
  • The poisonous material must be kept locked.
  • Fuming cupboard must be used where toxic, irritating and flammable vapors are involved. Exhaust fans I blowers must be kept continuously on to drive out any fumes or vapors if present.
  • While handling toxic and corrosive chemicals, use the proper personal protective equipment.
  • Do not throw used solvents into the sink but, collect them in containers for recovery or disposal.
  • There are energy lines and taps in the laboratory. Get them inspected periodically and see that leaks are detected and rectified quickly.
  • While pouring solvents which develop static charges from bigger container to smaller container, both of them must be earthed and bonded in order to prevent fire and explosion due to static charge buildup. Pour in the manner such that the free fall of the solvent is minimum.


  • Know the hazards of the chemical you deal or work with.
  • Make sure you have a copy of the MSDS, read and understand it.
  • Use appropriate personal protective equipment while handling the chemicals.
  • label all chemical containers and bottles correctly.
  • Store the chemical as per the incompatibility.
  • Obey warning and danger signs.
  • Use eyewash and safety shower with plenty of water when you come in contact with a chemical (for minimum 20 minutes).
  • Try to stop the spillage, if any, and report the same to the shift in-charge and safety department simultaneously through your colleagues earliest possible.


  • Store the cylinder in well-ventilated place/cylinder cage.
  • Ensure the color coding of the cylinder as per IS (Indian Standard) specification.
  • Do not drag gas cylinder. Use trolley for transport of cylinder.
  • Always store and use the cylinder in upright position.
  • Always chain the cylinder to prevent accidental knocking out.
  • Always use a pressure reducing regulator free from oil and grease attached to the cylinder valve.
  • Keep the metal cap in place to protect the cylinder valve.
  • Before removing the regular from the valve closed the valve and remove the gas by using the regulator.
  • Use appropriate personal protective equipment while handling the cylinders
  • Keep the valve of the cylinder closed whenever not in use.


  • All new equipment should be procured as per user's safety requirement and designed accordingly.
  • The equipment should be qualified for installation, operation, and performance.
  • The Persons working on the equipment should undergo the operation training.


  • Use the right tool for the job.
  • Immediately report all faulty equipment to your senior or departmental engineer.
  • Take extra care of your tools. Keep them clean and in good working condition. Replace damaged or worn out tools.
  • Do not carry tools in your pocket. Use a proper toolkit or box.
  • Use appropriate personal protective equipment while working or carrying out any repair jobs.
  • Make sure all guards and safety devices are in place and functioning properly before operating any power tools.
  • Electrical power tools must be properly earthed.
  • Do not operate electrical equipment with wet hands or while standing on a wet ground.

12. Office Safety:

  • Step stools should be used to obtain objects from higher shelves.
  • Chairs are meant for sitting, do not use them for another purpose.
  • Drawers must be kept closed when not in use to avoid people bumping on it.
  • Do not run electrical or phone cords across the aisles, cubicles or hallways as it becomes tripping hazards.
  • Be sure not to roll chairs or equipment over cords to avoid damaging its insulation and creating shock hazards.
  • Do not read while walking.
  • Slow down and look at blind corners along passageways and hallways.
  • Handle metal filing clips with care to prevent cuts.
  • Never lift anything which you cannot carry and always bend your knees while lifting a load from the ground to prevent back injury.
  • Always wash your hands before having your meals.


  • Ergonomics is the study of how people interact with their work. The Goal of the ergonomics programme is to minimize health hazards and psychological stresses.


  • Every moving part or every dangerous part of any machine must be properly guarded to prevent the accident.
  • Guarding must be compatible and must be able to restrict the access of any person to any moving or dangerous part.
  • Following types of guards should be provided as applicable.
  1. Fixed guard
  2. Automatic guard
  3. Interlocking guard
  4. Trip guard
  • Depending on the machine to be guarded its use/application, the operation of the machine, movement of the operator and another person, above types of guards must be selected.
  • Warning / Caution label must be displayed prominently near the moving or dangerous part of the machine and/or guard must be highlighted.
  • The machine should not be operated without the guard. If the guard has been detached from the machine then caution/warning label should be displayed prominently on the machine.


  • Following work permit procedures are to be followed while carrying out the respective work.


For the following activities hot work permit should be taken :

  • Gas Cutting
  • Welding
  • Brazing
  • Drilling
  • Chiseling
  • Buffing Grinding
  • Any work where the open fire is required viz. Tar heating or chances of spark generation hot work permit will be issued to user department after evaluation of the site condition with help of checkpoints mentioned in the hot work permits and clearance will be given by safety person for carrying out the job safely.


  • For the engineering jobs or activities, not specified in hot work permit or excavation permit, the cold work permit is required except if the vessel entry is done by the production person, for cleaning the vessel.
  • The user department will issue the permit after evaluating the site conditions where the actual job is to be carried out with the help of checkpoints mentioned in the cold work permit.


  • For the activities / confined space (Viz. - inside the reactor, vessel, tank) Vessel entry or confined space entry permit should be taken.
  • The vessel entry / confined space entry permit will be issued to user department after evaluating the site conditions where the actual job is to be carried out, with help checkpoints mentioned in the confined space or vessel entry permit. Electrical isolation wherever required will be done by the authorized electrical person. Final clearance will be given by safety Person after evaluation of site conditions viz. Gas in PPM level, explosive level in percentage electrical isolation, isolation of utility valves, etc.


  • For the excavation, work permit for excavation should be taken. The excavation permit will be issued to user department after evaluation of the site conditions where the actual job is to be carried out by Civil Engineer along with the electrical engineer and user department, with help of checkpoints mentioned in the work permit for excavation. Final clearance will be given by safety person after ensuring the site condition.


  • For the isolation of fire alarm system Fire alarm system isolation permit should be taken. The permit will be issued to user department / Electrical Department after the clearance given by Health, Safety and Environment department person.


  • For isolation of fire hydrant system, Fire hydrant system isolation permit should be taken. Fire hydrant system isolation permit will be issued by the Engineering department after the clearance from Health Safety and Environment Department. Same should be authorized by Unit Head/Engineering Head. This will be informed to all departments. The system will be restored after the completion of the job.


  • For the activities specified hereunder, the Electrical isolation permit should be taken.
  • Working on High Tension lines
  • Working on transformers
  • Working on main panels.
  • The permit with be issued after the evaluation of the site conditions where the actual job is to be carried out by electrical engineer along with the department head or another senior electrical engineer, with help of checkpoints mentioned in the electrical isolation permit. Final clearance will be given by Health, Safety and Environment department after ensuring the compliance of the permit conditions. After completion of the work in a given period, permit user wilt to inform it to the authorized electrical engineer who will restore the isolation after certifying the job.


  • In case of fire, break the glass of the nearest manual call point and try to alert person s in the immediate area of danger and / Of dial an emergency phone number and inform another person about the location of the fire and/or use fire bell.
  • Attempt to extinguish the fire using the nearest suitable firefighting equipment, without exposing yourself to undue risk.
  • If you are familiar with the plant. machinery or equipment affected by the fire isolate it as necessary for containment and to avoid further spread of the fire.
  • If the fire is from electrical power, do not use water until the main supply is switched off.
  • Send a report of the same to the unit head through HOD safety department
  • Nobody is allowed to get water from hose reel and hydrants except to put off the fire.
  • Strictly obey "No Smoking in instructions.
  • A fire drill will be carried out every month. Educate and expertise every person in firefighting by nominating them in these drills.


  • Special care must be given to prevent spillage of hazardous chemicals especially flammable solvent into the drain and sewage system.
  • Any spillage must be reported to the Health Safety & Environment Department immediately while possible control and containment of the spill is carried out.
  • All departments are provided with spill control kits. The emergency safety cupboards are located at various locations containing personal protective equipment and spill control kit.


  • EMERGENCY: A situation created by an accidental release, spill of any hazardous gas or chemical. fire. explosion. natural disaster or another situation which poses threat to the safety of employees. the environment or the property. The emergency can be declared by Raising walling siren, by announcing on public address system.


  1. By moving to a safer location break the glass of the nearest manual call point and try to alert persons in the immediate area of danger and/or dial the emergency phone number and inform another person s about the location of the fire and I or use of the bell.
  2. Attempt to extinguish the fire using the nearest suitable firefighting equipment, without exposing yourself to undue risk. First, seek to protect yourself by moving to a safer location.
  3. If you are familiar with plant, machinery or equipment affected by the fire, isolate as necessary for containment and to avoid further spread of fire.



  1. First, seek to protect yourself by moving to a safer location.
  2. Break the glass of the nearest manual call point and try to alert person s in the immediate area of danger and/or dial an emergency phone number and inform another person about the location of fire and /or use of the fire bell.
  3. Cover your nose with a gas mask or wet cloth & breath through it.
  4. All hot work should be stopped.
  5. Attempt to stop Leakage/spillage without exposing yourself to undue risk.


Immediately on receiving the communication to help.

  1. Hand over the current job to the colleague and proceed to the emergency control room for the site.
  2. Report to the incident controller at emergency control room/site.
  3. Follow the instructions given by the incident controller.


  • When told to evacuate or after hearing evacuation siren do not get panic.
  • Do not approach the emergency site as a spectator.
  • Do not engage phones unless it is in connection with the emergency.
  • Do not move about unnecessarily.
  • Remain at your workplace & be attentive to receive instructions.
  • Non-emergency team members should take charge from emergency team members
  • Proceed to Assembly Point in an orderly manner as per the emergency evacuation plans displayed in the department.
  • Ensure that all contractors & visitors working in your department are also following the above instructions
  • At the Assembly, point follows the instructions given by the department head.


  • Unit head will be the chairman of the committee.
  • Health, Safety and Environment Committee shall meet as often as necessary but at least
  • once in every month.
  • Employees will be a member of the committee.
  • Health, safety and Environment committee shall meet as often as necessary but at least once in every month.
  • Health, Safety and Environment Committee shall have the right to ask for necessary
  • information concerning Health and Safety of the employees 10 any personnel in the unit
  • and seek any relevant information advise concerning Health and Safety of the employees from an expert in the field.
  • Functions and duties of the Health, Safety and Environment Committee shall include :
  • Assisting and co-operating unit management in achieving the aims and objective outlined in Health, Safety and Environment Policy.
  • Dealing with all mailers concerning Health, Safety, and environment and to arrive at Practicable solutions to problems encountered.
  • Creating Safety awareness amongst all employees through safety team and Health. Safety & Environment committees.
  • Undertaking educational training and promotional activities for Safety. Health & Environment.
  • Deliberating on reports of Safety. Environmental and Occupational Health Surveys. emergency plans. safety and its risk assessment and implementation of recommendations made in the report.
  • Carrying out Health and Safety surveys and identifying causes of the accident or likely hazards and/or to appoint a team to carry out the same.
  • Looking into any notice on the probability of an imminent danger to the Safely and Health of the employees and to suggest corrective measures.
  • Reviewing the implementation of the recommendations made by it or by the authorities.
  • To discuss out the points raised in departmental Safety Committee Meeting.
  • The minutes of the meeting must be recorded. Minutes must contain all the points discussed in the meeting with the appropriate action to be taken, compliance did on the points discussed in the last meeting and the pending points for which compliance is not done.


  • When you find any unsafe condition. hazard. or an unsafe act by anyone in the company premises. prevent it if you have been adequately trained or immediately report it to your superior or Department. Head to avoid any unplanned incident.
  • The Employee operating a machine without authority.
  • An Employee using unsafe equipment.
  • Employee bypassing safety procedures.
  • Working without proper PPE.


  • As a part of the regular training program, Job Safety training should be carried out at different levels of the management.
  • As a part of 'Off the job' safety and in order to create awareness for Health, Safety and Environment training on the subjects like Vehicle Safety, road safety etc to be carried out at different levels of management.
  • Emergency handling training is a must for all emergency handling team members.
  • Firefighting training should be organized in the Cipla Colony for the employee's family.


  • All emergency handling team members will be trained in first aid.
  • First Aid boxes shall be available in all departments.


  • To create the Health, Safety and Environment awareness at all levels of management and to communicate the specific risk/hazards, at relevant locations Health, Safety and Environment Signs, Warning Labels, Instruction to be displayed.


  • Illumination sufficient for maintaining safe working conditions shall be provided where ever personnel is required to work or pass, including in passageways, stairways, and landings.
  • No work area shall have the illumination of less than 50 lux or an otherwise specified.


  • All machinery and equipment should be maintained clean.
  • The working area, pathways. Corridors. passages, restrooms. control rooms, substations, and washrooms should be free from rubbish and unwanted material.
  • Materials should be stored and stacked in such a way as not to cause any obstruction in the workplace or which could cause.
  • No materials should in such a way that it obstructs the accessibility to fire extinguishers, first aid boxes, electrical switches, walk paths aisles and roads.
  • No material should not be stored outside the demarked area.


  • Hearing protection devices shall be provided and used in areas where the noise level exceeds 90 dB (A) and when all other controls have been applied to reduce the level.
  • There should be proper ventilation for fumes and dust to prevent its concentration as it could be hazardous.
  • Noise monitoring as per the legal requirement s will be carried out as per schedule.


  • Only authorized and trained personnel are allowed to operate stacker.
  • No one is allowed to hitch a ride on these vehicles/machines.
  • Before starting the above-stated equipment the driver or user must go through a checklist or water and lubrication oil etc and report fault discovered.
  • Stacker s must have reverse buzzers.
  • All goods hoist and personnel lift must have an annual inspection by a competent person.


  • List of key personnel is available at an emergency control centre, main gate. Please refer the same in case of emergency.


  • The hazardous wastes must not be mixed with normal wastes. It must be stored separately.
  • These wastes should be handed over to Health Safety & Environment Dept with details of waste in a prescribed format.
  • The waste shall be handed to Authorised party for disposal.