Industrial Safety Management (eBook)

Dr. J Maiti, PhD, Professor & Head, Department of Industrial & Systems Engineering, Indian Institute of Technology (IIT), Kharagpur, India has more than fifteen years of teaching, research and consulting experience on safety analytics, quality analytics, engineering ergonomics, and engineering systems safety design and management. He excels in teaching multivariate statistical modeling, engineering systems safety design and control, safety analytics, work system design, quality engineering and design of experiments. Pradip Kumar Ray is presently a Professor in the Department of Industrial and Systems Engineering, Indian Institute of Technology (IIT), Kharagpur, India. He has published one text book titled ‘Product and Process Design for Quality Economy and Reliability’, nine book chapters, six lecture packages, and around 140 papers in international and national journals of repute and conferences in the areas of healthcare management, productivity measurement and evaluation, quality design and control, TQM, process optimization, ergonomics/human factors engineering, safety engineering and management and other related topics. His areas of interest and research include productivity modeling, quality engineering, ergonomics, safety engineering, engineering asset management and JIT-based/lean engineering operations management.

Preface 6
Contents 8
Safety by Design 10
1 Prevention Through Design: A Concept Note for Preventing Accidents/Injuries to Construction Workers 11
Abstract 11
1.1 Introduction 12
1.1.1 Study Background 12
1.1.2 Health Hazards in Construction 12
1.1.3 Research Study 14
1.2 Concept of Prevention Through Design 14
1.3 PtD for Construction 16
1.4 PtD for Health Hazards in Construction 17
1.5 Conclusions 18
References 18
2 Virtual Prototype based Simulator for EOT Crane 19
Abstract 19
2.1 Introduction 20
2.2 Virtual Prototype 21
2.3 Virtual Reality Application in Training 21
2.4 Advantages of the VR Training System 22
2.5 An Introduction to Simulators 22
2.5.1 Virtual Crane Simulator 22
2.5.1.1 Environment and Needs 22
2.5.1.2 The Crane Simulator 23
2.6 Methodology for Development of Crane Simulator 23
2.6.1 3D Modelling and Texturing 23
2.6.1.1 Coordinate Systems 23
2.6.1.2 Points, Lines and Faces 24
2.6.1.3 Image Mapping (Texture Mapping) 25
UV Mapping 26
Normal Mapping 26
Bump Mapping 26
Reflection Mapping 27
2.6.2 Animation 27
2.6.3 Immersive and Interactive Environment 27
2.6.3.1 Geometric Transformations 27
2.6.3.2 Lights, Cameras and Shading and Surface Characteristics 27
Lighting and Shadows 28
2.6.4 Interaction Implementation 28
2.6.4.1 Rigging 28
2.6.5 Setting up Collision Among Components 30
2.7 Results 32
2.7.1 Textured Models 32
2.7.2 Developed Virtual Environment 33
2.8 Conclusions 34
Acknowledgements 34
References 34
3 Reduction of Coal Dust Exposure Using Water Mist System 35
Abstract 35
3.1 Introduction 36
3.1.1 Dust as Health Issue for Workers 36
3.2 Materials and Methods 37
3.2.1 Objective 37
3.2.2 Design of Study 37
3.2.2.1 Sampling Sites 37
3.2.2.2 Personal Sampler 38
3.2.2.3 PM5 Sampling 39
3.2.2.4 Water Mist System 40
3.2.2.5 Statistical Analysis 40
3.3 Results and Discussions 41
3.4 Conclusions 42
References 42
4 A Study on Performance Parameters Associated with the Effectiveness of Antilock Braking System on Rough Roads 44
Abstract 44
4.1 Introduction 45
4.2 Principle of Antilock Braking System 45
4.3 Performance Parameters Affecting the Effectiveness of ABS on Rough Road Condition 47
4.3.1 Effect of Suspension on ABS 47
4.3.2 Effect of Tyre Oscillation 47
4.3.3 Vehicle Body Motion 48
4.3.4 Run-in-Effect of Tyre Force Generation 48
4.3.5 Sudden Changes in Wheel Speed, as the Wheel Encounters an Obstacle 48
4.3.6 Controller Algorithm 49
4.3.7 Tyre Model 51
4.3.8 Modelling of Test Vehicle 51
4.3.9 Road Condition Modelling 52
4.3.10 ABS Hydraulics 53
4.4 Scope for Further Work 54
4.5 Conclusion 54
References 55
Safety Analytics 57
5 Data-driven Mapping Between Proactive and Reactive Measures of Occupational Safety Performance 58
Abstract 58
5.1 Introduction 58
5.2 Data Collection and Preparation 61
5.3 Methodology 62
5.4 Results and Discussion 64
5.4.1 Mapping of Incident Root Causes Versus Safety Observations 66
5.5 Conclusion 67
Acknowledgements 68
References 68
6 Prediction of Occupational Incidents Using Proactive and Reactive Data: A Data Mining Approach 69
Abstract 69
6.1 Introduction 70
6.2 Methodology 73
6.3 Case Study 73
6.3.1 Data Set Generation 73
6.3.2 Data Preprocessing 74
6.3.3 Methods Used 75
6.3.3.1 C5.0 Algorithm 75
6.3.3.2 CART Algorithm 76
6.3.3.3 Adaptive Boosting 76
6.4 Research Results and Discussion 77
6.5 Conclusion 79
Acknowledgements 79
Appendix 79
References 81
7 Determinants of Risk Indices in Hard Rock Mine Using Loglinear Model 84
Abstract 84
7.1 Introduction 84
7.2 Methods 85
7.2.1 Variables 85
7.2.1.1 Age 85
7.2.1.2 Experience 86
7.2.1.3 Occupation 86
7.2.1.4 Location 86
7.2.1.5 Degree of Injury 86
7.2.2 Loglinear Model 87
7.2.3 Estimation of Parameters 88
7.2.4 Data Collection 91
7.3 Results and Analysis 92
7.3.1 Injury Rate Analysis 93
7.3.2 Loglinear Modelling 98
7.3.3 Risk Estimation Using Loglinear Model 99
7.3.4 Discussion 102
7.4 Conclusions 102
7.5 Limitation of the Study 103
References 103
8 Mathematical Modelling of Human Energy Consumption During Hand Arm Vibration in Drilling Operation for Female Operator 105
Abstract 105
8.1 Introduction 106
8.2 Literature Review 106
8.3 Operational Methodology 107
8.4 Mathematical Modelling 108
8.4.1 Development of Mathematical Model 108
8.4.2 Identification of Variables or Quantities 108
8.4.3 Drilling Operation (Independent Variables) Parameters 108
8.4.4 Formulation of Field Data-Based Model 109
8.4.5 Mathematical Model for Female Operator 109
8.5 Artificial Neural Network Simulation 110
8.5.1 Human Energy by Artificial Neural Network (ANN) 110
8.5.2 ANN Model Development 110
8.5.3 Human Energy Calculation from Field Value 112
8.5.4 Sensitivity Analysis of Drilling Operation 112
8.6 Results and Discussion 113
8.6.1 Performance Analysis of Drilling Operation Model 114
8.7 Conclusion 115
References 115
9 Modelling the Perception Towards In-Vehicle Distracted Driving Among Four-Wheeler Drivers in Kerala 116
Abstract 116
9.1 Introduction 117
9.2 Problem Statement 118
9.3 Objective 118
9.4 Methodology 118
9.5 Results and Discussion 119
9.5.1 Structural Equation Model 119
9.5.2 Recommendations 124
9.6 Conclusions 125
References 126
Safety Management 128
10 Assessment of Significance of Safety Life Cycle Management (SLCM) Approach Using IEC61508 Safety Standard Towards Its Implementation in the Foundry Shop: Case Study of a Pump Manufacturing Industry 129
Abstract 129
10.1 Introduction 130
10.1.1 Safety Instrumented System (SIS) 130
10.1.2 IEC 61508 Safety Standard 131
10.1.3 Safety Integrity Level (SIL) 131
10.1.4 Safety Life Cycle (SLC) Model 132
10.2 Motivation 132
10.3 Case Study and Problem Formulation 133
10.4 Methodology of the Study and Mathematical Computations 134
10.4.1 Analysis Phases 134
10.4.1.1 Mathematical Computations (To Determine the SILs Using LOPA Method) 137
10.4.2 Realization Phases 137
10.4.3 Operation Phases 137
10.5 Results and Interpretations 138
10.6 Conclusions 140
References 140
11 Understanding the Human-computer Interaction Behavior in Electrical and Power Systems 142
Abstract 142
11.1 Introduction 142
11.2 Literature Survey 144
11.3 Research Methodology 145
11.4 Results and Discussion 145
11.5 Investment and Cost Analysis 148
11.6 Conclusion 149
References 149
Author Index 151
Subject Index 153