Page 42 - The Insurance Times April 2025

Case Study

Workplace Safety and Health - Addressing

Accidents in Manufacturing Plants

Executive Summary tailed investigation by the Occupational Safety and Health
Directorate.
Workplace safety and health are critical to ensuring em-
ployee well-being and sustaining productivity in manufactur-
ing environments. Manufacturing plants, due to their reli- Root Causes of the Accident
ance on heavy machinery, hazardous materials, and high- Upon investigation, several factors contributed to the acci-
speed operations, are prone to occupational hazards. This dent:
case study explores a real-life incident at a mid-sized auto- 1. Mechanical Failure: The hydraulic press had not under-
mobile component manufacturing plant in India, where a gone scheduled maintenance, leading to a failure in the
severe accident led to the injury of three workers. The analy- pressure release valve.
sis identifies the root causes, evaluates the corrective and
2. Inadequate Safety Training: The injured workers were
preventive actions taken, and provides insights into best
temporary hires who had not received proper safety
practices for maintaining a safe work environment. Through training or orientation.
the lens of this case, we emphasize the significance of imple-
menting a comprehensive workplace safety management 3. Absence of Safety Guards: The machine lacked proper
system. safety guards that could have contained the errant
components.
Introduction 4. Poor Supervision: Supervisory personnel failed to en-
Manufacturing industries are integral to economic develop- force safety protocols and machine operation guidelines.
ment but are also among the sectors with the highest rates
of occupational injuries. According to the International Corrective Actions Implemented
Labour Organization (ILO), over 2.78 million workers die The company, following the accident, implemented several
annually due to work-related injuries and diseases, with a immediate and long-term corrective actions:
substantial number from manufacturing sectors. Ensuring Machine Maintenance Overhaul: All machinery under-
workplace safety in such environments is not only a legal went immediate inspection and maintenance. A preven-
and ethical obligation but also essential for operational ef- tive maintenance schedule was institutionalized.
ficiency and employee morale.
Safety Infrastructure: Safety guards and emergency
shut-off systems were installed on all critical machines.
Incident Overview
Employee Training: A comprehensive safety training
In March 2023, an accident occurred at XYZ Components
program was launched, mandatory for all employees in-
Pvt. Ltd., a manufacturer of automotive engine parts in
cluding contract workers.
Pune, Maharashtra. Three workers sustained serious inju-
ries when a hydraulic press malfunctioned, causing a sud- Safety Committee Formation: A cross-functional safety
den release of mechanical parts. The accident halted op- committee was formed to conduct monthly safety au-
erations for two days, leading to financial losses and a de- dits and recommend improvements.

38 April 2025 The Insurance Times