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Plant Safety || Textile Plant Safety

Updated: Dec 22, 2023


Safety is defined as being free from the occurrence of accidents.


The Accident is defined as an unplanned and uncontrolled event in which an action or reaction of an object, person, substance, radiation results in a person’s injury.

Classification of Accidents

Significance of safety in Industry

Accident-free zone and safe atmosphere will result in improvement in the work culture.

  • It will increase productivity.

  • It will decrease the less labor turnover.

  • It will increase the profits of the company.

  • It results in the harmony of the company.

Cost aspects of Accidents

There are 2 types of costs.

  1. Direct Cost

  2. Indirect cost

Direct cost

It’s related to accident history like downtime cost, medical expenses, etc.

It also includes the exgratia of the worker's family.

Indirect cost

It includes below.

  1. Cost of production

  2. Cost of machine replacement

  3. Cost of training a worker.

Advantages of safety program in an industry

  1. Increased productivity

  2. Lower labor turnover

  3. Improves production

  4. Improved labor-management relation

  5. Substantial reduction in direct and indirect costs

Causes of accidents:

Unsafe acts of person:

  1. Taking unsafe posture or position

  2. Unsafe loading/placing

  3. Using unsafe equipment

  4. Making safety devices inoperative.

  5. Operating at an unsafe speed

  6. Failure to use protective devices

The unsafe mechanical condition of the machine

  1. Poor ventilation

  2. Bad light or glare

  3. Improper height

  4. Defective, rough, sharp, slippery area of machine

  5. Unsafe cloths

  6. Unsafely arranged or poor housekeeping

  7. Not wearing mask/goggles or earbuds.

  8. Unsafe process(chemical/electrical/Nuclear)




Practically preventable



Safety Measures

  1. Improved physical and mechanical conditions

  2. Precautions are taken for the new machine

  3. Providing protective equipment

  4. Good housekeeping & odor

  5. Periodic inspection of machine and methods.

  6. Committed management

  7. Workers cooperation

  8. Strong and stable Trade unions

  9. Safety postures

  10. Safety contest

  11. Safety day/week

  12. Safety training

We can measure the accidents from the below formulae.

Interpretation: Safe-t-score is a dimensionless number and it is a statistical tool for measuring the rate of accidents.

+ve Number= Worsened situation

-ve Number= Improved situation

If the score is between +2 & -2 change is not significant.

If the score is >+2 record is significantly worst.

If the score is <-2 record is better.


Given the following data with respect to the industry at 2 different locations for 2 different places. Carry out safe-t-score test and interpretation.

Location X:


10 accidents

10^4 hours


15 accidents

10^4 hours

Location Y:


1000 accidents

10^6 hours


1100 accidents

10^6 hours


Compare to 2 locations, location X is better.

In location X even though the accidents increased by 50%, the change is not significant.

It is in the range of -2 to +2

The situation in Y is worsen as t is >+2.

A 10% Increase in accidents is highly significant.

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