Logistics Safety

21st October, 2016

Dimension & Complexity of LH India (outbound primary)

Dimension
Fleet Size

ACC
19K
Darlaghat / Rauri

Driver Population

28K

Total Routes

5K

High Volume
Routes

1.0K

Ropar
Bathinda

Primary Road
Distance(KM)
Travel per Month

Tikaria

Lakheri

13 Million

Rabriyawas

P
a
l
i

Surat

Harsh Terrain

Gagal
R Nalagarh
Bat op
Roorkee
Asian
ar
hin
da
Dadri I & II

2.7 Million

(Part of Primary Road

Distance(KM) Travel per
Month)

Ambujanagar

Ti
ka
ria
Kymore
Ky
mo Sindri
Chaibasa
re
Bhatapara

Jamul
Ch
Chan
an
Maratha drapur
da

Farraka
Damodarh
Sankrail

Bargarh

Chanda

BCCI
Panvel

Harsh terrain routes are of state of Himachal Pradesh, Uttarakhand &

Kerala
Mangalore

Prioritization is key for ensuring effectiveness of

actions e.g. first focus on 20% high volume
routes and most risk prone drivers

La
kh
eri

W
Wadi
a
d
i
Kudithini

Thondebhavi
Cochin

Madukkarai

Integrated Plant
Grinding Station
Terminal
ACL
ACC

Logistics Safety Journey so far !!!

Phase 1 &
Phase 2
mandatory
steps

Safety score index through

GPS, IRSP, JRM, Driver
RFID, GPS, Suraksha Management Centre, more
Kawach (Seat Belt), structured Consequence
Management,
MOU with
CSM (Cat. 4),
transporters,
Simulator training,
Transporter & Driver
Wave 3
engagement,
2015-16

Wave 2
2014-15

Wave 1
2012-14

Current initiatives Outbound primary

(IRSP & Plant Hygiene factors)
Basic
Facilities

Driver amenities,
basic infrastructure

Vehicle

Driver

Vehicle checklist

Driver passport

Seat Belt convincer

Driver Simulator

Reward &
Recognition

OEM camps
DDT/ DMC
Vehicle passport

Toilets/ Bathrooms,
rest room

Community

Engagement
3rd party certification

Canteen, Cooking
area

Transporter

In-vehicle
monitoring systems
(RFID/ GPS)

Driver counselling
based on JRM/
GPS
Health camp,
insurance camp

Awareness
campaigns around
plant, e.g.
community
education

Reduce
dependence on
market trucks*
5% annual
increase in volume
through controlled
fleet to be explored

Right set of initiatives which need to be strengthened by rigorous implementation and

application of a unified approach consistently across the LH India
4

Outbound logistics - Current initiatives at Warehouses

Hygiene
factor

WH
staff

Labour
DSCQP

Ergonomics
training

Safety
awareness

Check list based

audits

Health camp,
insurance camp

CFA
engagement

Mechanization

Communication

Assessment/
mitigation of 5
fatal hazards

Basic facilities Canteen and cooking facilities

Basic facilities Rest room, Washrooms

Basic facilities Parking yard

Basic facilities Safety corner, Driver training room

Basic facilities Alcohol consumption test equipment

10

Use of technology in logistics safety

RFID

GPS

Expected
loading time
alert at yard
to driver
Fatigue
Management

Reduced
congestion

Reporting to
plant for
loading as
per preassigned/
announced
sequence

Physical
Movement of
drivers/
helpers

Order
allocation
visibility at
yard,
reduced
getting down
inside plant

Vehicle
count
control

Auto cap on
vehicles
inside plant
at any point
of time

Parameter

Measurement Criteria

Default values

Speed Limit

GPS Device speed

65 Kmph /10 sec

Harsh driving
(Acceleration)/ Harsh
Braking

Vehicle gains quick speed

or stops in a very short
time

15 Km/sec (rapid
acceleration / deceleration
respectively)

Harsh Maneuver

Vehicle takes a very sharp

turn quickly with a set
speed

> 15 degree @ 45 km/ hr

or higher speed for HCV

Continuous driving

Continuous driving
duration for a vehicle

180 mins or 150 Km

whichever is less with
stoppage < 15 mins

Power disconnect

Device is migrated from

vehicle power to internal
battery

Supply voltage dropping

below 6 V

Night drive

Vehicle running between

11 PM to 5 AM

Speed grater than 5 Kmph

for more than 30 minutes
during night hours

Note: Driver rating for night drive is

deactivated while rating
1
1

GPS safety parameter violation trend

Continuous Drive

Harsh Maneuver

Harsh Brake

GPS safety parameter violation is showing a

reducing trend. To be further reduced through
DMCs

12

GPS safety parameter violation trend

Over-speed

Sudden Acceleration

GPS safety parameter violation is showing a

reducing trend. To be further reduced through
DMCs

13

Use of Seat Belt Convincer

Seat Belt Convincer successfully
used to demonstrate to the truck
drivers the importance of wearing
a seat belt whilst driving.

The Seat Belt Convincer is a crash simulator training

device that helps to expose drivers and passengers to
the forces of a low speed crash to reinforce the benefits
of wearing a seat belt whenever the vehicle is in motion.

Presentations & Road Show

Presentations on
the importance
of wearing seat
belt made by
road safety
expert

Nukkad Natak
(road
show)staged on
the Seat Belt
theme

OH&S MOU signed by Transport Contractors

MOU signed by all Transport
Contractors, committing
themselves to align themselves
with ACCs OH&S goals and
Safety Improvement Plan relating
to Vehicle, Driver and Journey
Management

Driver training on Truck simulator

6000 drivers
will be trained
at all plants in
2016

JRM Chanda to Nagpur route

Puncher shop at
19.2, 19.4km,
Garages for heavy
vehicles around,
Police Stn. Padoli
at 19.8km, Traffic
flow as
approaching Padoli
junction rush traffic
due to shops &
garages also by
college and school.
At 16.1km
[Link] Devi
Ayurvedic College
and Hospital,
Unpredictable
movements by
pedestrians /
children / autos /
cycles are
expected. Medium
Risk before
approach to Padoli
junction.

SAMPLE
Road loose gravel and bad
near bridges and diversions,
over all plain without markings,
Single road start at 10.4km,
Men at work due to road road
extension, single road start at
10.4km and double road with
diversion at 11km, At 12.9,
13.9km diversion end and
single road, Double road at
13.1km, At 14.5km diversion
end and double road, Single
road at 19km. Road single
occupied by shops and
establishments with vehicle
parking when approach to
Padoli intersection.

10 to 20 km
section

Risk Factor:

High

Medium

Diversion from
Ghugus

12.2 KM

13.6 KM

19.0 KM

19.9 KM

Transporter Collaboration/Partnership and Engagement Model

and Community Education
Improve awareness on road safety in the

Build
Transporter Profile

Institute
Awards/Rewards
Program

community as follows:
Rate
Transporters

A. On vector 0 5 kms in the first 6 months,

thereafter additional
En-route schools and colleges

Building
Transporter Partnership
Model

Dhabas ( 5 nos. )
B. Within 5 kms radius (in association with
CSR)

Formalize Transporter
Engagement Programs

Design & Roll-out

Transporter
Scorecard

Schools & colleges

Panchayats
Self help group
Farmer Club
Govt. bodies

19

Transporter Engagement

LH India overall incident analysis outcome key areas to

focus
Driver Behaviour
DDT for each and every drivers

DMC at all plants for trip based

counseling

Behavior based skills to be

monitored for controlled drivers

3rd party evaluation mandatory every

6 months by authorized
OEM/Service centers

Old vehicles to be phased out

Vehicle
Revisit vehicle checklist for
additions

3rd party (Pedestrian/Motorcyclist)

Installation of SUPD* (both sides) for
controlled vehicles

SUPD* (both sides) mandatory for

controlled & uncontrolled (market) vehicles

*SUPD = Side Underride Protection Device

20

LH Incident Reporting Classification & Investigation

(Version 2015-10-22 HSST IRC&I_v1)
4. Classification and Reporting Process
AS-IS
4.1 Incidents at a LafargeHolcim Location
4.2 Incidents at a Non-LafargeHolcim Location
4.3 Reporting
All incidents are internally reportable. Once they are deemed recordable according to the rules of this Standard,
they are included in the Groups statistics.
4.3.1 Transporter reporting
Transporters that have an exclusive contract with the Group are considered to be under our management
control, for the purposes of incident reporting and classification. Any work-related incident that doesnt fall
under the conditions specified in section 4.4 are recordable.
Transporters that are transporting for the Group and other companies will be under Group management
control when our product/material is transported, or they are traveling empty, but their journey's purpose is to
collect our product/materials. Management control ceases once they have delivered their last load and left
the premises, and any incident that happened after that are not considered recordable.
4.4 Recordability Exceptions
All incidents are recordable except under the following conditions.
4.4.1 Natural causes / Human events
4.4.2 Travel to and from assigned work location
4.4.3 Criminal or illegal acts by members of the public
4.4.4 Non-work-related activities on company premises
4.4.5 Other events and activities not considered work-related are as follows:
Those occurring before or after an employee's work shift or on a break

21

Legacy Holcim Risk Matrix Basis used for activity

Risk is the combination of the likelihood of a specific unwanted event and the potential consequences should it occur

Likelihood

Risk Classification Matrix

Almost
Certain

15
Medium

10
High

6
High

3
High

1
High

Likely

19
Medium

14
Medium

9
High

5
High

2
High

Occasional

22
Low

18
Medium

13
Medium

8
High

4
High

Unlikely

24
Low

21
Low

17
Medium

12
Medium

7
High

Rare

25
Low

23
Low

20
Low

16
Medium

11
Medium

Insignificant

Minor

Moderate

Major

Dramatic

Consequence

Qualitative parameter for LIKELIHOOD

Level Descriptor Description
Almost
The event is expected to occur in most
A
Certain
circumstances
The event is will probably occur in most
B
Likely
circumstances
C
Occasionally The event should occur at some time
D
Unlikely
The event could occur at some time
The event may occur only in exceptional
E
Rare
circumstances
Qualitative parameter for CONSEQUENCE
Level Descriptor Description
Multiple Fatalities, toxic release off site with
Dramatic /
1
detrimental effects, huge financial loss,
Catastrophic
consistent regular intervention or prosecution
Single fatality, Permanent disability, extensive
injuries, loss of production capacity, off site
2
Major
release with no detrimental effects, major
financial loss, consistent adverse attention by
media
LTI serious, on site release contained without
3
Moderate
outside assistance, high financial loss, major
client aggrieved
MTI, on site release immediately contained
4
Minor
mediam financial loss, some client
dissatisfaction
First aid treatment, on site treated injuries, low
Insignificant
5
financial loss, no significant change, no media
/ Negligible
attention

22

Process work flow outbound distribution

Plant vicinity

Vehicle/ driver at
parking yard

Queue for plant

entry

Driver/ Vehicle
checks

Reversing
Parking
Repairs
Cooking
Personal hygiene

Congestion
Waiting

Drivers authorizations
Alcohol testing
Vehicle condition

Inside plant

Journey

Driver movement
Vehicle movement
Reversing
De-tarping/ Tarping
Managing Congestion

Reversing
De-tarping/ Tarping
Congestion
Unsafe Driving
Fatigue
Continuous driving
Vulnerable road users

Consignee
location

Navigating unsafe
conditions, including
vulnerable road users
Unauthorized parking

De-tarping
Unloading
Reversing
Vehicle movement

Drivers skill, ability to perceive hazards, manage risks, general state of readiness and vehicle condition
are some of the critical factors across the flow which impact the likelihood of an accident
23

Risk Assessment outcome outbound primary

Likelihood

Risk Classification Matrix

Almost Certain

Likely

2 activities
(14)

1 activities
(9)

4 activities
(5)

Occasional

2 activities
(18)

5 activities
(13)

9 activities
(8)

Unlikely

1 activities
(17)

1 activities
(12)

Rare

Outbound Primary

Insignificant

Minor

Moderate

Major

Dramatic

Consequence

24

RED Risk activities outbound primary

Risk
Classification

Consequence /
Likelihood /
(Risk rank)
Location
Major /
Likely /
(5)

RED

Major /
Occasional /
(8)

Moderate /
Likely /
(9)

Plant vicinity (offsite)

Description of Activity
Vehicle entry from main road to
company road

Sub activity
Vehicle movement around plant vicinity

Plant parking yard

Plant parking yard
Plant parking yard
Plant parking yard
Plant Gate

Vehicle movement
Vehicle movement
Actual parking
Other personal activities
Vehicle check

Internal movement within yard

Reversing at yard
Parking
Minor repairs / breakdown
Vehicle non-complying to check-list

Plant Gate

Driver authentication

Unauthorized / Untrained driver plying

vehicle

Plant Gate
Inside plant
Journey (Plant to destination)
Journey (Plant to destination)
Journey (Plant to destination)
Journey (Plant to destination)
Consignee location
Consignee location

Alcohol consumption by driver

Tarping
Dispatch and delivery of cement
Dispatch and delivery of cement
Dispatch and delivery of cement
Tarping
Vehicle movement/ placement
Vehicle movement/ placement

Alcohol check found positive

Vehicle placement and reversing
Vehicle movement on public road
Unauthorized/ unsafe parking en-route
Repairing due to breakdown en-route
Vehicle placement and reversing
Parking/ Placement
De-tarping

Plant vicinity (offsite)

Unauthorized parking

Unauthorized parking

25

Process work flow warehouse

Warehouse vicinity

Unsafe driving
Vulnerable road users
Unauthorized parking
Minor repairs
Unauthorized / unsafe
parking
De-tarping/ Tarping

Warehouse bay/
Transshipment point

Vehicle placement
Reversing
Manual / Mechanized
unloading/ unloading

Inside warehouse

Unsafe Stacking
Illumination
Infrastructure
Civil/ Electrical
maintenance
Ergonomics
Shutter operations

Management of risks associated with vehicular movement are largely dependent on driver and vehicle.
Warehouse facilities and operations are very basic, and mostly manual in nature. However, controllability
improves as we move from left to right of the flow
26

Risk Assessment outcome warehouse

Likelihood

Risk Classification Matrix

Almost Certain

Likely

Occasional

1 activities
(14)

5 activities
(9)

1 activities
(5)

3 activities
(13)

1 activities
(8)

Unlikely

1 activities
(17)

2 activities
(12)

1 activity
(7)

Rare

Warehouse

Insignificant

Minor

Moderate

Major

Dramatic

Consequence

27

RED Risk activities warehouse

Risk
Classification

Consequence /
Likelihood /
(Risk rank)
Major /
Likely /
(5)

Location

Description of activity

Sub activity

Warehouse vicinity

Vehicle entry and exit: main road to

warehouse premises

Approaching warehouse

Shutter operations

Manual/ Mechanized operations of shutters and

gates

Warehouse vicinity

Vehicle parking

Detarping

Warehouse bay

Loading / Unloading

Manual loading / unloading

Warehouse bay

Loading / Unloading

Mechanized loading / unloading

Warehouse premises /
road

Transshipment

Manual loading / unloading

Inside warehouse

Stacking

Stack height, aisle space, safe storage,

ergonomics of manual operations

Inside warehouse

Stacking

Stack height, aisle space, safe storage,

ergonomics of mechanized operations, machine
operations

Dramatic/ Unlikely/
Inside warehouse
(7)
Major /
Occasional /
(8)

RED

Moderate /
Likely /
(9)

28

Risk Assessment outcome secondary

Journey

Consignee location
Unsafe driving
Vulnerable road users
Unauthorized parking
Minor repairs
Unauthorized / unsafe parking
De-tarping/ Tarping

Likelihood

Risk Classification Matrix

Almost Certain

Likely

Occasional

Unlikely

Rare

Secondary

Vehicle placement
Reversing
De-tarping/ Tarping

5 activities
(7)

5
Insignificant

4
Minor

3
Moderate
Consequence

2
Major

1
Dramatic

29

RED Risk activities secondary

Risk
classification

RED

Consequence
/ Likelihood / Location
(Risk rank)

Major /
Occasional /
(8)

Description of activity

Sub activity

Journey (warehouse to destination)

Dispatch and delivery of cement

Vehicle movement on public road

Journey (warehouse to destination)

Dispatch and delivery of cement

Parking

Journey (warehouse to destination)

Dispatch and delivery of cement

Repairing due to breakdown

Journey (warehouse to destination)

Dispatch and delivery of cement

Vehicle deployed for consignment delivery

Journey (warehouse to destination)

Dispatch and delivery of cement

Driver engaged for consignment delivery

Consignee location

Vehicle movement/ placement

Parking/ Placement

Consignee location

Vehicle movement/ placement

Detarping

30

Risk prioritization
Red risk Controllable

Priority P1

Red risk
Partially
controllable

Priority P1

Yellow risk Controllable

Priority P1

Red risk
Non
controllable

Priority P2

Yellow risk
Partially
controllable

Priority P2

Risk identified in for all processes prioritized on the basis of criticality and controllability. We recommend
that Priority 1 (P1) risks be addressed immediately and Priority 2 (P2) risks be addressed subsequently
31

Risk Assessment outcome & prioritization Outbound (Primary)

Location

Description of Activity

Sub activity

Mitigation Theme
Controllable

Vehicle entry from main road to

Plant vicinity
company road
(offsite)
Unauthorized parking
Vehicle movement
Vehicle movement
Vehicle movement
Plant parking Actual parking
yard
Other personal activities
Other personal activities
Other personal activities
Other personal activities
Yard out to Gate queuing
Parking yard
Yard out to Gate queuing
to plant gate
Document submission, inspection
Plant Gate

Vehicle check
Driver authentication
Alcohol consumption by driver
Vehicle movement inside plant

Journey
(Plant to
destination)
Consignee
location
Total

Dispatch and delivery of cement

Dispatch and delivery of cement
Dispatch and delivery of cement
Tarping
Vehicle movement/ placement
Vehicle movement/ placement

Controllable

P2
P2

People, Infrastructure
People
People, Infrastructure
People, Infrastructure
People, Infrastructure
People, Infrastructure
People, Infrastructure
People, Infrastructure
People, Infrastructure
People, Process

Vehicle movement

People, infrastructure, process

P1

Unsafe vehicle movement

People, infrastructure, process

P1

Alighting and boarding, physical movement

Vehicle non-complying to check-list
Unauthorized / Untrained driver plying vehicle
Alcohol check found positive
Unsafe vehicle movement

People, infrastructure, process

Process
Process
Process
People, Process

Alighting and boarding, physical movement

Vehicle placement at packing plant
(truck)
Vehicle movement and reversing
Vehicle placement at packing plant Vehicle movement and reversing, Lid
(bulker)
opening/closing
Tarping

YELLOW
NonControllable

Vehicle movement around plant vicinity

Unauthorized parking
Entry / exit at yard
Internal movement within yard
Reversing at yard
Parking
Cooking
Personal grooming, resting, freshen up
Unauthorized physical movement
Minor repairs / breakdown

Truck weighment at weigh bridge

Inside plant

RED
Partially
Controllable

Vehicle placement and reversing

Vehicle movement on public road
Unauthorized/ unsafe parking enroute
Repairing due to breakdown enroute
Vehicle placement and reversing
Parking/ Placement
Detarping

P1
P1
P1
P1
P1
P1
P1
P1

P1
P1
P1
P1
P1

People, Infrastructure, Process

P1

People, Infrastructure, Process

P1

People, Infrastructure, Process

P1

People, Infrastructure, Process

People
People
People
People, Infrastructure
People
People, Infrastructure

P1
P1
P1
P1

P2
P2
P2
5

11
32

Risk Assessment outcome & prioritization Warehouse

Location

Description of activity

Sub activity

Vehicle entry and exit: main

road to warehouse premises Approaching warehouse
Vehicle movement & parking Unauthorized parking, Reversing outside godown

Mitigation
Theme

Vehicle parking

Detarping

Vehicle parking

Minor repairs / breakdown

People, Process

Loading / Unloading
Warehouse
bay
Loading / Unloading

Placement of vehicle for loadiing/ unloading

People, Process

Manual loading / unloading

Loading / Unloading
Warehouse
premises /
road
Transshipment

Mechanized loading / unloading

People, Process
People, Process,
Infrastructure

Stacking
Stacking
Inside
warehouse Shutter / gate operation
Infrastructure repairs
Labour
Total

P2

People
People
People,
Infrastructure
People,
Infrastructure
People,
Infrastructure

Warehouse Vehicle movement & parking Reversing outside godown, Parking

vicinity
Vehicle parking
Personal grooming, resting, freshen up

RED
YELLOW
Partially
NonPartially
NonControllable Controllable Controllable Controllable Controllable Controllable

Manual loading / unloading

People, Process
Stack height, aisle space, safe storage, ergonomics
of manual operations
People, Process
Stack height, aisle space, safe storage, ergonomics People, Process,
of mechanized operations, machine operations
Infrastructure
People, Process,
Manual/ Mechanized opening / closing of shutters Infrastructure
People, Process,
Civil / electrical maintainenance, illumination
Infrastructure
Health of labour, usage of PPE, emergency
People, Process,
response
Infrastructure

P2
P1
P1
P2
P2
P1
P1
P1

P2
P1
P1
P1

P2
P2
4

33

Risk Assessment outcome & prioritization Secondary

RED
Partially
NonControllable
Controllable

Location

Description of activity

Sub activity

Mitigation
theme

Journey (warehouse to destination)

Dispatch and delivery of cement

Vehicle movement on public road

People

P2

Journey (warehouse to destination)

Dispatch and delivery of cement

Parking

People

P2

Journey (warehouse to destination)

Dispatch and delivery of cement

Repairing due to breakdown

People

P2

Journey (warehouse to destination)

Dispatch and delivery of cement

Vehicle deployed for consignment delivery

People

P2

Journey (warehouse to destination)

Dispatch and delivery of cement

Driver engaged for consignment delivery

People

P2

Consignee location

Vehicle movement/ placement

Parking/ Placement

People

P2

Consignee location

Vehicle movement/ placement

Detarping

People

P2

Total

34

Theme : People

Driver Management Center scope

First entry

Defensive Driver
Induction

2 hrs

CV, UCV

One time Plant induction,

Dos & Don'ts, H&S rules, amenities,
emergency response,
Vehicle/ Driver expectations

Once a year

DMC Scope

Defensive Driving
Training

CV

1.5 days

Daily - per shift

Tool Box Talk

30 min

CV, UCV

Comprehensive Defensive driving

skills syllabus as per RSG document,
Simulator

Alert sharing, Seasonal inputs

Vehicle & driving related inputs
Fatigue

Daily per trip

Counseling
10-15 min

CV, UCV

Trip counseling (previous & new trip),

JRM, Seat belt usage

Quarterly, Half yearly, Annual

Driver Loyalty /
Engagement program
Frequency

2 hrs

CV, UCV

Duration

Medical camps, insurance camps,

OEM camps, reward & recognition

Coverage

CV controlled vehicle,
UCV uncontrolled vehicle

35

DDT Defensive Driving Training (Purpose & contents)

Purpose :
To raise defensive driving skills, visual perception skills, knowledge of Vehicle limitations and drivers responsibility to other road
users.
To provide drivers with an awareness of actual and potential hazards associated with driving on all types of roads in the area of
company operation and equip drivers with the necessary defensive driving skill and techniques to recognize these hazards,
understand the defence and act in time.
Contents

1. Introduction and overview

I. Causes of accident
II. Statistics of accident
2. Indian traffic scenario
3. Hidden cost of human life
4. Typical aggressive behaviour
5. Be a defensive driver
6. Traffic signals
7. Road signs
8. Road markings
9. Safety devices
10. Safe parking

11. Safe distance between vehicles

12. Overtaking: when, where and how
13. Steering grip
14. Emergency vehicles
15. Night driving
16. Driving in special conditions
17. Road user behaviour
18. Effect of alcohol on driving
19. Causes of accident
20. How to avoid accidents
21. Mirror adjustment and positioning

36

Theme : People

Case study Driver Management Center @ Tikaria

37

Theme : People

Contents and coverage

Defensive driving

Traffic control devices

Plant/parking yard
safety rules

GPS based debriefing

Stress and fatigue

Safe braking distance

Hazard perceptions

JRM

Night driving

Rules of the road

Vulnerable road users

Experience sharing
by drivers

Responsible driver

Incident alerts sharing

First aid

Pre/ Post Training

assessment

Operational hours :
2 shift operations
08:00 hrs to 16:00 hrs 1 trainer,
14:00 hrs to 22:00 hrs 2 trainers

Modality :
One to Two Counseling
Classroom Training
Pre Post Assessment of Drivers

Drivers Coverage:

Drivers Training Status:

All Cement Truck Drivers (Outbound Vehicles)

All Flyash Bulker Drivers (Inbound Vehicles)
All Company Owned Vehicle Drivers
All Employees
Contractors and their workers (Transport Supervisors,
Traffic Marshals, Packing House labors, etc)

Training period : Mar15 - 31st Dec15

Total number of unique drivers trained : 2796
Training period : Jan16 - July16
Total number of unique drivers trained : 1857

38

Theme : People

Tracking mechanism and outcomes

Date

Trainer
Name

Driver
Name

Driver Id

Driver License
Number

Transporter
Name

Vehicle
Number

SUNEEL 98383891
MAA VAISHNO
1/7/2016 MUKESH YADAV
35
UP5120070000824 TRPT. CO. UP42AT2134
MAA VAISHNO
BUDHI 99840477
1/7/2016 MUKESH RAM
69
UP5119930000522 TRPT. CO.
UP42T9495
Month
July'16
Plant
Average dedicated truck count for last quarter
(Apr-June'16)
Average GPS Truck count for last quarter (AprJune'16)

GPS

Smartphone
User
Training Topics

YES

NO

DANGEROUS OF
OVERSPEED

NO

DANGEROUS OF
OVERSPEED

NO

95

85

DATE

30/7/2016

ZAID

30/7/2016

ZAID

NAME
SARAD
KUMAR
GURU
MEET
SINGH

2015

2016

84

80
D => Dedicated

M =>
Market

75

585

2013

H => Hybrid
Driver counselling
GPS counselling
Total
Total Dedicated Dedicated Truck
MTD
Total GPS
GPS vehicle MTD GPS
drivers
Truck for the Coverage(uniqu DedicatedT vehicles for the coverage(uniqu Truck
gone
day (Dedicated e truck nos) for otal Truck
day
e truck nos) for coverage(
Total no of Vehicle
Driver
through trucks covered the day. (Use coverage(u
the day (Use
unique
Driver checked @
Date Registered
counselling in the day)
each dedicated nique truck
each GPS truck truck nos)
Registered daily
for the day
nos)
driver only once
on the day
driver only once
[D]
till date random
(Count For
[D]
in the month)
in the month)
the day)
[D-Fresh
[D-Fresh drivers]
[D+H+M]
drivers]

TRAINER
NAME

94

90

Tiakria (N212)
469

94
92

PRE POST ASSESSMENT TEST (Full Marks-30)

DRIVER LICENCE
Vehicle
DRIVER MOB
NUMBER
TRANSPORTER
Number
THE RAMPUR
MORADABAD
9917133518 UP2120040039869
TRPT. CO.
UP21N3417
JAI MAA VINDHA
VASINI
9457638563 UP6519870005137
ROADLINES
UP31T7921

2014

Pre DMC GPS Score

PRE TEST POST TEST

MARKS
MARKS

16

19

20

24

Post DMC GPS Score

Pre-training assessment score :

14.64 / 30.
Post-training assessment score :
23.36 / 30.
An improvement of approx. 30 %

39

Theme : Hardware/ Infrastructure

Hardware/ Infrastructure Hygiene factors

Safety begins with us i.e. our plant locations
It is essential to provide basic infrastructure and amenities to
drivers and transport community at our plants

Infrastructure/ Hygiene factor :

Parking yard
Separate entry/ exit points at yard/ plant

These amenities will make their work-life usually filled with

hardships, long tiring journeys in often hostile conditions a safe
place to rest and be prepared for next trip.

Driver rest room, Toilets/ Bathrooms

It also conveys the message we indeed mean safety of all

stake holders in our eco system

Illumination

Canteen / Cooking area

Tarping / De-tarping facility

Bulker lid operation facility
Develop a charter of basic minimum standards

Safety device for bulker operation

Positive barricading

Assess current amenities w.r.t. standards - for availability, adequacy

and sustainability

CCTV monitoring
Traffic flow layout

Build, upgrade through Capex / Opex, 3rd party outsourcing in 2 waves

Concreting in parking yard

Monitoring and maintenance

40

Theme : Hardware/ Infrastructure

Hygiene Factors at ACC plants

O-1 Traffic Flow & Parking layout
O-2 Signage's/barricading
O-3 PPE for drivers
O-4 Mobile phone usage
O-5 Tarpaulin tying
O-6 Marshalls/ Traffic Patrollers
O-7 Reversing rule
O-8 Responsibility for material shifting
O-9 Drivers yard amenities
O-10 Parking yards illumination
O-11 Eliminate use of hydra
O-12 Housekeeping in Loading areas
O-13 Reversing cameras
O-14 Random checking/quarterly checking
O-15 Traffic Marshall training

L-1 Driver and vehicle certification

L-2 Logistics contracts
L-3 Driver and vehicle passports
L-4 Self checking of vehicle and drivers
100% checking of DL, PPE and alcohol
L-5
testing.
L-6 Contractor Supervisor
L-7 LSO training
L-8 Safety Corner in Parking Yard
L-9 Consequence management

Plant/Unit
Vizag

O-1

O-2

O-3

O-4

O-5

O-6

O-7

O-8

O-9

O-10

O-11

O-12

O-13

O-14

O-15

BCCI
Jamul
Thondebhavi
Sindri
Gagal
Madukkarai
Chanda
Chaibasa
Wadi
Damodhar
Bargarh
ACC,Kudithini
Lakheri
Kymore
Tikaria

Plant/Unit
Vizag

L-1

L-2

L-3

L-4

L-5

L-6

L-7

L-8

L-9

BCCI
Jamul
Thondebhavi
Sindri
Gagal
Madukkarai
Chanda
Chaibasa
Wadi
Damodhar
Bargarh
ACC,Kudithini
Lakheri
Kymore
Tikaria
41

Theme : Hardware/ Infrastructure

Vehicle
14000 controlled fleet
Mostly older vehicles ply in cement industry trend of new sophisticated vehicles like prima etc getting engaged but
at a very slow pace
Due to age of vehicle low focus into investment for maintenance by transporters
Resistance from unions
Consequence management on unfit vehicles not stringently applied

42

Theme : Hardware/ Infrastructure

Vehicle - standard
VEHICLE INSPECTION FORMAT - Quarterly by third party

BULKER INSPECTION CHECKLIST

VEHICLE INSPECTION CHECKLIST

Checklist Serial No.

Checklist Serial No.

Date : _____ /______ /_________

Date : _____ /______ /_________

Name of Transporter:

Vehicle Regn.
No.

Name of Transporter:

Driver Name /DL No:

[Link].

Driver Name /DL No:

Description

Plant:

Name of Transporter:

Mobile no:

[Link].

Plant:

Rear View Mirrors on both sides

Horn in working order

Reverse alarm & reverse lights in working order

Windscreen without any cracks

Head Lights & Rear lights in working order

Paddle brakes in working order

Hand brake in working order

Windscreen wipers in working order

All tyres (including spares) in roadworthy condition (treads not worn out)

10

Retractable 3-point Seat Belt for driver

Suspension system is even and balanced and shockers, leaf springs
and shocker mounts are properly secured and not broken, corroded
or bent.
Integrity of electrical wiring and wire harness with no loose or joint
wires or compromised insulation (which can cause wires to overheat
leading to a fire due to an open or short circuit), including
recommended rating of fuse fitment

Description

Yes/No

DRIVER

Driver has valid Driving Licence and renewed (as applicable)

Driver passed Alcohol Test (Blood Alcohol level)

Driver has PPE (Safety Helmet, Safety Shoes and Reflective Jacket)

DRIVER

Driv er has valid Driving Licence

VEHICLE

Driv er passed Alcohol Test (Blood Alcohol level)

Valid Bulker testing certificate as per "Factories Act" is available

(Check for expiry date)

Driv er has PPE (Safety Helmet, Safety Shoes and Reflective Jacket)

RC Book / Fitness Certificate/ Insurance/PUC documents available

and renewed (as applicable)

VEHICLE

Yes/No

RC Book / Fitness Certificate/ Insurance/Pollution documents available

Head Lights & Rear lights in working order

Comments

Comments

Safety valve is fixed on air line

Head Lights & Rear lights in working order

Brakes in working order

Brakes in working order

10

Hand brake in working order

Hand brake in working order

11

Windscreen wipers in working order

12

All tyres (including spares) in roadworthy condition (treads not worn out)

13

No hazardous goods kept inside the Cabin (Stove / Kersone etc.)

14

Outlet hose is free from any wear & tear and attched with four bolts
to bulker tanker

15

Windscreen wipers in working order

All tyres (including spares) in roadworthy condition (treads not worn out)

10

No hazardous goods kept inside the Cabin (Stove / Kersone etc.)

11

Rear Under-run Protection Device (RUPD) & Side Under-run Protection Device (SUPD) on right &
left side available and not in damaged condition

11 point truck check list (SUPD included)

Yes/No

Yes/No

Comments

Comments

Presssure guage is fixed on air line

Date : _____ /______ /_________

Vehicle
Regn. No.

Mobile no:

[Link].

Checklist Serial No.

11

12

Vehicle
Regn. No.
Description

13

Side Indicators and parking lights in working order

14

Wheel Nut-Bolts : all are present and properly secured

16

First Aid Box available and updated

17

OE fitment of Radiator cap

18

No visible Oil Leakage

All coupling latches are available on air line and material line

19

Tool Box (Jack/Handle) available in vehicle

16

Butterfly valve on air line and material line is available

20

Reflective Strips on sides and rear

17

SUPD

21

SUPD

17 point bulker checklist (SUPD included)

Transporter engagement and MoU with transporters

OEM/ 3rd party vehicle certification, maintenance, phasing out vehicles older than 15 years
Enforcement of stringent consequence management on non-compliance
Phasing out vehicles older than 15 years in a time bound manner

Comments

21 point 3rd party check list (SUPD included)

Build
Transporter
Profile

Focus on improvement in road worthiness of vehicles through:

Detailed plan to be presented in next version

Yes/No

Institute
Awards/R
ewards
Program

Building
Transporter
Partnership Model

Formalize
Transporter
Engagement
Programs

Rate
Transporters

Design &
Roll-out
Transporter
Scorecard
43

Warehouse safety Initiatives on labour engagement

CFA/ Warehouse owner engagement

Awareness of Safety for warehouse staff and labour
Warehouse road show
Shramik Suraksha Varta Sensitizing labour on
House keeping
Usage of PPE
Ill effects of tobacco, smoking etc.
Fire safety
Vehicle related hazards and safe practices

PPEs (sensitizing on usage)

Surprise visits by Central PMO crack team
Logistics safety review at regional meetings
Fortnightly review by Regional Leadership Team

44

11 point check-list, 5 fatal hazards

Types

Paramaters
Stacking Height
Bag Stacking
Marking of 6 inches width to be painted on the walls
Stacking procedure is "header & stretcher"
Basic Amenities Clean Drinking Water
Illumination inside warehouse and loading area during
Adequate
operational hours
Illumination
Outside warehouse during operational hours
Warehouse floor clear of loose objects (tarpaulin,cement
Good
bags,tools,etc)
Housekeeping
All access and walkways free
Nose Mask usage
PPE
Safety Shoe usage
5 standardized posters displayed
Safety Posters
Prints MSDS of cement available and/ or displayed
and Signages
Display of emergency contact nos. at prominent place
First Aid Box
Contents as per latest version and with valid useful life
Expiry (valid useful life and valid pressure of the
extinguisher)
Availability - atleast One dry chemical Powder fire
Fire extinguisher
extinguisher of 9 kg
Maintenance (regular testing and servicing by authorised
agency)
Electrical Safety Safe electrical points with no loose/ open connections
Emergency
light/torch
Available in working condition
Shutter
inspection
All shutter inspected as per standardised checklist

Hazard
Category Parameters
Clear and sufficient access for godown from the road
Vehicle movement inside the godown (eg. Reversing)
Vehicle Positioning of vehicle for loading / unloading (risk related to placement of vehicle)
and
Vehicle maintenance activities inside godown
Traffic
Wind screen cleaning activity inside godown
Vehicle roll over during loading / unloading
Vehicle dala condition (dala sturdiness to bear load of labour standing on it)
All electrical sockets are in good condition
Electrical Proper electrical fuse are present
connecti All electrical cables are properly tied
ons
All electrical points (fan, light) are properly covered
Pins are fitted to all electrical equipmet cables
Determined maximum stack height
Bag stacked in header and stretcher fashion
Bag
No cement bags should be stacked in contact with an external wall. A clear space
Stacking
of at least 60 cm should be left between the exterior wall and the stacks
Aisle space of minimum 60 cm in between the stacks
Curtains are OK with no rusting and glide smoothly
Hood Cover is OK with no rusting / bend damages
No damage to bracket plate
Shutter
All holdfasts are firmly inserted in the walls and no physical damages observed
Stoppers are in place
Guide channels are OK / without any bend damage and greased properly
Concrete / Brick / Stone masonary
Columns
DSCQP ISBM Stanchions with AC sheets/ GI sheets, Partially wall & Partially AC/ GI Sheets
RCC roof
Trusses structure and purlin

45

Warehouse shutter check list

Names of Inspection Team
Name of CFA
Address of Warehouse

Tick (P), whichever applicable

Sr. No.
DESCRIPTION
1

Curtains are OK with no rusting and glide

smoothly

Hood Cover is OK with no rusting / bend

damages

No damage to bracket plate

All holdfasts are firmly inserted in the walls

and no physical damages observed

Stoppers are in place

Guide channels are OK / without any bend

damage and greased properly

Sr. No.
Sales Unit
Shutters
Dimension
L(height) X B

NA

Date

COMMENTS

3
5
6

46

Warehouse safety shutter mechanization solution

47

Warehouse safety - Mechanization

Need for mechanization :
Shortage of manpower- Manpower always not
available to the fullest requirement which
hampers the service level

Ergonomics- Manual handling of bags can

lead to health problems to the workers.

Cost of Labour- Increasing cost of labour.

Productivity Improvement Fast loading and

unloading.

Ease of operation- Mere increase in the

number of labour does not lead to ease of
operation

Features of mechanization :
Ease of Mobility
Ease of Operability
Enhanced Safety proRoad Maps
Extended horizontal coverage with added part
Wider Utility- used for both loading/ unloading
Ease of maintenance
48

Logistics Safety framework of skills, competencies and

behaviours
Implementation of LH
H&S Strategy

Ensuring adequate
H&S organisation

Manage incidents

Control hazards and

manage risks

FML ( AO logistics manager, Plant

logistics safety officer, warehouse safety
officers)

MML ( Supply allocation manager, rail &

road specialist, VCX head & coach,
analyst, SU & Plant Logistics manager) &
Corporate Logistics team

Ensures implementation of H&S activities

arising from ACC H&S Strategy

Ensures implementation of H&S activities

Determines and realizes an H&S roadmap for the area
arising from ACC H&S
Strategy
of responsibility
based
on the
ACC H&S
Strategy manager, rail &
FML
( AO logistics manager,
Plant
MML
( Supply
allocation

SML ( Head Central Logistics, Regional

Logistics Directors, Regional Logistics Manager)

Knows department budget and associated

levels of authority and delegation
Knows expected standards and level of
personal authority to deliver (entitled to; I
have the right to ask for)
Knows what must be reported in line with local
procedures

Raises any issues of capability or resources

honestly and accurately to aid resolution
Clarifies whats expected and what resources
are available in response to specific issues
Rigorously reports as required and actively
supports open reporting culture

logistics safety officer, warehouse safety

Know

road specialist, VCX head & coach,

safety officers)

Demonstrate

Fully engages H&S within activity and seeks

support to achieve best possible outcomes
Extracts and re-presents information relevant
to location and checks for understanding and
applications in the work areas

Plant Logistics manager) & Corporate

Has detailed working knowledge of Risk

Has detailed knowledge of key hazards within
Knows key hazards and associated control
Logistics
team of operation
Assessments related to activities being
sphere of operation which includes Journey
measures
within sphere
Defines performance expectations
into simple
operating
Ensures that H&S responsibilities
for next level
in area detailed
controlled, control
measures,
Risk Drives
Management
(JRM).Has
committed
and effective incidence
Drives committed and effective incidence
objectives for self and procedures,
reports
of responsibility is defined
and buildofinto
Performance
permits to work etc.
knowledge
agreed
control measures for
management
management
Clarifies expectations to ensure decisions and
Management process
key hazards
expectations are consistent with regard to
Demonstrates clear understanding of capital

Has
detailed
knowledge
of
incident

Has
detailed
knowledge of procedures in sphere
Know
resource allocation
requirement and reflect in functional budget
management
protocols
in sphere of
of operation for incident response
ActEnsures all indicators
collected inrefreshes
a timely knowledge
Takes
of H&S
indicators
within his
sphere
Ensures that control measures for key hazards
are
Continuously
ofownership
actual
Reviews
operation
against
requirements of
operation
Has
knowledge
escalation process and upward
and thorough manner practices and ensures consistency
of operation
in sphere
of operation
areof
effective
with
RAs, JSAs
, JRMs etc. for effectiveness of
Has detailed knowledge of investigation Ensures framework
reporting of safety operation tours
required safe operation
controls
protocols
in
sphere
of
operation

Has
detailed
Monitors quality and quantity of SOTs* in
covering their sphere ofknowledge
operation of investigation process
sphere of operation
Takes personal interest in underpinning
Takes personal interest in underpinning attitude of
attitude to safety of direct reports
performance
Responds to incidents as per procedures,
Act of direct reports Ensures own personal knowledge and carry
Positively recognizes good standards whilst
Presents case with conviction. out training / drills in line with local and
establishing control of immediate situation
driving hard on poor ones, share accountability
Consistently communicates the value
of honest
and
corporate
procedures
Ensures upward communication is commensurate
Shows personal leadership
to ensure
value for upholdsopen
reporting
Is visible
in workplace;
standards
of
Provides
Ensures
feedbackprompt
on levels
accurate
of effectiveness
reporting in the
Takes personal
interest inis
effectiveness
and information
retained forof
future learning
Demonstrate
honest reporting is unequivocally understood
Actively promotes reporting of non-injury events and
performance and behavior by dont walk by
of controls
andof
remedial
required
control
event
incidentactions
in lineas
with
local
measures
Ensures proactively
investigations are led effectively
safety concerns
Takes personal
interest
in quantity
and quality
Challenges to learn, improve or uphold
Ensuresprocedures
own SOT*s are done effectively and
Ensures
outcomes
are communicated
up and
those of Ensures
reports are
reviewed
and
feedback
of
tours
within
protocols are followed effectively
downframework
effectively including remedial actions
providedwhenever required
Shows personal commitment to own tours
(participation)
Know

Act

SML ( Head Central Logistics, Regional

Logistics Directors, Regional Logistics

Understands how to
ensure most effective use
Understands H&S roles
and responsibilities
officers)
analyst,
SU & Plant Logistics manager) &
Manager)
of available resources (human and otherwise)
Understands resource
requirements
(human and
Corporate
Logistics
team
Knows what acceptable standards of
capital) for area of responsibility
housekeeping in warehouse,
Actively manages
etc and key hazards by ensuring
Actively manages key hazards by ensuring
Ensures that critical hazards are identified and
maintenance of vehicles
that all related activities are implemented
that all related
activities
are implemented
FML ( AO
logistics
manager, Plant are managed
MMLeffectively
( Supply allocation manager, rail & road
Knows what eventsthoroughly
need to be reported and
thoroughly
logistics safety officer, warehouse
specialist, VCX head & coach, analyst, SU &
what the output profile should look like

SML ( Head Central Logistics, Regional

Logistics Directors, Regional Logistics
Manager)
Drives committed and effective incidence
management

Demonstrate

Takes incident management capability of

self and reports seriously and ensures
confidence in combined capability
Raises any concerns in combined
capabilities before foreseeable events
Secures area and information post incident
and actively participates in learning process
to generation information for others

Challenges self and others of knowledge and

required actions in response to foreseeable
incident scenarios
Regularly checks for aligned understanding of
requirement up the line
Personally checks investigations in sphere of
operation for quality of output
Communicates learning from others incidents
with interpretation of local relevance to team

Knows overall incident processes and procedures

Knows the process of incident investigation
Understands logistics H&S indicators reactive and
proactive indicators.
Demonstrates understanding of statistical
relationship incident-injury
Ensures that all FTE in the sphere of his
responsibility know expectations regarding
processes and procedures
Ensures investigation findings are timely and
accurate
Ensures findings are communicated up the chain of
command
Ensures action plans are updated to prevent
repetition
Does incident-injury consistency checks and acts
upon them
Confirms capabilities prior to event to deliver
expected outcome
Ensures that action plans in sphere of responsibility
remain accurately prioritized
Shows personal commitment to learning / sharing
and eliminating repetition

Framework has 4 main elements, and it

outlines the expected and observable
behaviours for each of them
These expected and observable
behaviours cover frontline, middle and top
management levels
Recommend that this framework be
adopted for logistics safety Road Map 2020
Organisation for delivery of Road Map
2020 varies across ACC and ACL, as well
as outbound and inbound logistics
operations. Important issues to consider,
for example:
Can the organisation working on
outbound logistics also support
inbound, which has just got off the
starting block?
Inbound has no resources centrally to
drive safety. Is it needed? If not, how
can this responsibility be managed?
Separate logistics safety organisation
v/s embedding it within the overall
safety organisation working in
tandem with the function?
Recommend that all of the above be
addressed systematically by Oct 31, 2016

49

Current Logistics Organization (Outbound only)

MD & CEO

CMO

Regional Logistics Director

Head Central Logistics

Supply allocation
Regional
Logistics
Manager

Supply
Allocation
Manager

Rail & Road

Specialist

VCX head
& coach

Analyst

IT Project
Ops

SU Logistics Manager
Plant logistics Head and Team

Infra/projects
MIS / Analyst

AO Logistics Manager

Warehouse safety Officer

Logistics Safety &

Business PMO
Team

Plant logistics Safety Officer

Regional Logistics Safety

Officer

50

51