MANUFACTURING ACTIVITIES COVERED UNDER THE FACTORIES ACT, 1948

16 industries have been identified as major accident hazard unit as follows:

List of Major Accident Hazard Factories under Jharkhand Factories (Control of Major Accident Hazard) Rule

TABLE - 1

Sl.No.	Name of the Factory	No. of Workers Employed
01)	The Tata Iron & Steel Co. Ltd., Jamshedpur	32,000
02)	B. O. C. India Ltd., Burma Mines, Jamshedpur	N A
03)	Bokaro Steel Plant, Bokaro
04)	ANIROX Pigment Ltd., Govind Pur, Dhanbad	N A
05)	Jai Prabhu Jee Iron & Steel (P) Ltd., Koudra, Govind Pur	N A
06)	Bharat Petroleum Co. Ltd., Station Road, Chuttia, Ranchi	N A
07)	Bihar Caustic & Chemical Ltd, Rehla Palamu	N A
08)	Indian Oil Corporation Ltd., Namkum, Ranchi	N A
09)	Usha Martine Ltd., Wair Ropes & Specialty Production Division, Tatigilwar, Ranchi
10)	Hindustan Petroleum Corporation Ltd. Hazaribag, (Bottling Plant)	N A
11)	Hindustan Petroleum Corporation Ltd., Ranchi Road, Marar Hazaribagh	N A
12)	Patrau Thermal Power Plant, Hazaribagh	N A
13)	Indo Asahi Glass Co. Ltd., Hazaribagh	N A
14)	Heavy Engineering Corporation Ltd., Ranchi
15)	Indian Explosive Ltd., Bokaro	N A
16)	I. A Corporation Ltd., Dhanbad	N A

Details of no of workers employed in these factories, name of the hazardous chemicals handled, quantity of hazardous chemicals stored/handled and the threshold quantity prescribed is not available with the Office of the Chief Inspector of Factories.

The list of hazardous industries as per 2(cb) of the Factories Act in the state of Jharkhand are given below:

TABLE – 2

LIST OF HAZARDOUS INDUSTRIES IN JHARKHAND (2002- 2004)

Year	No. of Industries	No. of Workers
2002	74	26367
2003	78	26510
2004	80	26619

Manufacturing Activities of a few large & medium industries are described below:

Jharkhand is the home to the largest steel plant in Bokaro, apart from Jamshedpur being practically the city of TISCO and TELCO.

Steel Industry

Tata Steel - The Tata Iron & Steel Company Limited (TATA Steel) is one of the best managed steel companies in India. The patriot industrialist Jamsetji Nusserwanji Tata set up the company in 1907 at Jamshedpur in Jharkhand. The company is one of the lowest cost producer of steel in the world.

Energy efficient technologies, optimum utilisation of raw materials and state-of-the-art equipment have made Tata Steel India's single largest producer of sophisticated steel. The no of workers employed in TISCO are given below:

Table - 3

No of workers employed

	Year
	2002	2003	2004	2005
Regular Employees	16934	16085	17039	15670
Contract Labour	12706*	13643*	15342*	17070*

* These figures varies as construction work requirement.

TATA Steel's all steel making facilities are located in Jamshedpur, in the state of Jharkhand. It owns several iron-ore mines, collieries and flux mines located near its plant. TATA Steel manufactures diverse range of products and offer services. The products include forging quality steel, rods, HR/CR coils and sheets, tubes, construction bars, strips and bearings, structurals, ferro alloys and other minerals, steel plant and material handling equipment, software for process control and cargo handling services.

The latest major modernisation initiatives are the reconstruction and capacity enhancement from 0.6 mtpa to 1.0 mtpa of the 43-year old "F" Blast Furnace at less than half the cost of a new blast furnace and the installation of the Submerged Entry Nozzle and Electro Magnetic Stirrer in the Biller caster # 1 of LD # 1.

A Strategic partnership has been forged with Nippon Steel Corporation and Arcelor for knowledge sharing in the Auto sector. Talks are on with Vivendi Water India Ltd. for water management, Gartner have been engaged to evolve a long term Information Technology strategy. An e-governance programme has been initiated with the help of Stern & Stewart. A new JV, TM logistics, has been formed for logistic management and port operations. The first steps in the Ferro Chrome project in South Africa have been initiated.

TATA Steel achieved its highest ever first half (April - September 2002) production by notching 1.8 MT and highest ever first half sales at Rs. 4,034.30 crores. It has also achieved highest ever first half profits after tax at Rs. 269.10 crores; an increase of 462% over last year.

TATA Steel's efforts to brand its products have reaped dividends with the sale of Tata Shaktee (GC Sheets), Tata Tiscon Rebars, Tata Bearings and Tata Pipes, growing by 15% overall. Similarly, sales to the critical Auto segment have achieved a 35% growth and the Company's market share in the Cold Rolled products was buoyant at 29%.

Lower raw material consumption by 8%, lower energy consumption by 3%, higher labour productivity by 6% and lower interest burden by 25% are some of the operational parameters that have contributed to this excellent performance.

The merger of Tata - SSL will further strengthen the Company's financial and market presence.

Bokaro Steel Plant

Bokaro Steel Plant (BSP) is situated in the coal belt and Indian engineering and equipment suppliers have played a major role in its construction - the first indigenous public sector integrated steel.

BSP has a capacity of 4 million TPA of crude steel. The quality of its products are appreciated internationally. The continuous casting facilities have been recently installed and the Hot Strip Mill have been revamped which has provided the state-of-the-art-technology to BSL for manufacturing international quality steel. Its SMS - I, SMS -II, Continuous Casting Shop, Slabbing Mill, Hot Strip Mill, Hot Rolled Coil Finishing & Cold Rolling Mill Complex have ISO : 9002 certification.

The Steel Plant had received ISO-9002 certification for most of its units.

BSP has a value added products like SAILCOR (Corrosion Resistant Steel), API Grade Steel, SAILPROP, SAILMEDS, SAILRIM, HRND, SAILMA, WTCR, BSL-46 for auto sector.

It has a capacity of 4.5 million tonnes of liquid steel & 3.78 million tonnes of saleable steel.

Product Mix	Tones/Annum
HR Coils, Plates & Sheets	21.20 lac
CR Coils & Sheets	13.90 lac
GP/GC Sheets	1.70 lac
TMBP	1.00 lac
TOTAL SALEABLE STEEL	37.80 lac

The main products of Bokaro Steel Plant are :

o Basic Grade Pig Iron.

o Mild Steel Hot Rolled Sheets in Coils and Plates.

o Concast Mild Steel Slabs.

o Mild Sheet Cold Rolled Sheets in coils.

o Prime Hot Dip Galvanised plane sheets and coils.

o Prime Hot Dip Galvanised corrugated sheets.

o Tin Mill Black Plates.

Accident Statistics of BSP during the year 2004.

Sl. No.	Types of Accident	Regular	Contractor	Total
1.	Non-Reportable a) First Aid Cases b) Loss time injuries	749 169	11 08	760 177
2.	Reportable a) Reportable non fatal b) Fatal	23 03	02 00	25 03
3.	Man-days lost (including fatal)	20057	86	20143
4.	Man-hours worked	68632800	5301600	73934400
5.	Frequency rate (on the basis of 2 a+ 2 b)	0.38	0.38	0.38
6.	Severity rate (including fatal)	292.24	16.22	272.44

Promotional Activities during the year 2004.

a)

a) Saturday Awareness Workshops (SAW) were organized with Union/Worker’s representatives on every Saturday.

b) Safety Tableau was presented for mass awareness on 26/01/04 at Kumarmangalam Stadium during the Republic Day Parade.

c) Safety Exhibition stalls was put up during Swadeshi Mela & Basant Mela. Safety appliances/Models were displayed, Safety Literature/Pamphlets distributed and Video Films on Industrial Safety shown. Safety Quiz competition was organized among visitors of Swadeshi Mela. The winners were given prizes on the occasion of National Safety Day-2004.

d) National Safety Day was celebrated on 4^th March, 2004. As a part of it awards were given for following competitions to various deptts and individuals concerned:-

- Safety & Housekeeping (15 depts.).

- Territory Upkeep (10 deptts.).

- Zero Accident during last 3 years (2 deptts.).

- Most Safety Conscious Workers (69 workers.).

- Safety Quiz (3 citizens).

e) Road Safety Awareness Seminar was inaugurated by MD on 05/07/04 at Kala Kendra, Sector-2, Several safety activities were carried out during Road Safety Campaign like Motorcycle rally through township roads, Traffic regulation by NCC Cadets & Security personnel at vulnerable road crossings, Placards on road safety were displayed and pamphlets on road safety were distributed. ED (P&A) distributed prizes to schoolchildren for elocution & drawing competition in the concluding function on 09/07/04.

Spectrum of Safety Activities of BSP during the year 2004.

a) All accidents and dangerous occurrences were investigated. Corrective measures were recommended and implemented status was regularly monitored. These measures resulted in reduction in number of accidents.

b) Cost of accidents were calculated on regular basis and discussed at various levels. Evaluated figure is Rs. 1.42 crores during 2004 against Rs. 1.52 crores during 2003.

c) 19 Nos. Workshops were organized during the year 2004 and participated by 840 employees.

Sl.No.	Topic of the Workshop	Dept./Unit	Date	No. of Participants
1.	Safe Operation’ of EOT Cranes	CRM	16/03/04	35
2.	Safe Operation of Trippler	RMHP	17/04/04	20
3.	Safety in Iron Making	SAIL Plants & RINL	22-23/04/04	19
4.	Safety in Steel Making	- Do -	04-05/05/04	21
5.	5 S Concept of Housekeeping	SED & OHS	21/05/04	25
6.	Hazards & Risk Analysis	IMF	25/05/04	35
7.	Safety Awareness	Traffic	03/06/04	85
8.	Aids Prevention	Traffic	03/06/04	75
9.	Material Handling	SMS-1	22/06/04	24
10.	Behaviour Based Safety	IMF	01/07/04	17
11.	Safety Communication	IMF	23/07/04	23
12.	Derailment Prevention & Safety	Traffic	28/07/04	62
13.	Accident Prevention & Stress Management	RMP & RED	06/08/04	27
14.	Crane Performance Improvement	SMS-1, CRM, IMF, BF, MS, SM & HSM	06-13/08/04	149
15.	Fire Fighting & Safety	CRM	11/09/04	45
16.	Safety Awareness	DNW	07/10/04	12
17.	Derailment Prevention & Safety Road Safety	Traffic	01/12/04	60
18.	Road Safety	SI. Mill, SF and Stores	13/12, 22/12 & 23/12/04	95
19.	Safety Workshop for Contractors.	CRM	22/12/04	11

Training Activities at BSP during the year 2004.

a) Safety Steward Training was organized during Jan.-Apr. 04 and 113 persons attended the programme. Live demonstration on Rescue operation was organized by WMD Team.

b) Training on ‘Conveyor belt Safety’ was imparted to 15 workers of RMHP on 26/10/04.

Sl.	Name of the Programme	Duration	Category	Participants
1)	Regular Safety Management	02 Days	(E6 – E7)	2004	2005
				99	90
2)	Safety & Accident Prevention	02 Days	(E0 – E5)	95	282
3)	Special Shop Floor	01 Day	(E0 – E5)	-	149
4)	Safety, Health & Fire Fighting	03 Days	(S1 – S10)	983	930
5)	Shop Floor Safety	01 Day	All Workers	11363	12066
6)	Road Safety	01 Day	All Workers	127	841
7)	Electric Safety	01 Day	Electricians	26	236
8)	Gas Safety	01 Day	Exe + N Exe	92	195
9)	First Aid	01 Day	All Workers	-	387
10	Contractor Safety Induction	01 Day	Contr.	17265	10193
11)	Shop Floor Safety	01 Day	Contr.	857	1596

Innovation & Development

a) Regular monitoring of 5-minutes safety briefing by the Shift I/c of Opn. & Maint. Of Major Shops in the beginning of each shift to arouse awareness among the employees.

b) Flying squad checking for use of PPEs by the employees at the workplace and Memos issued to the defaulters.

c) High-level inspection/Joint Committee inspection

d) Video-graphy of Unsafe Conditions/Practices in vulnerable areas.

Future Thrust Areas

a) Shop floor inspection by Apex Team – monthly One Dept.

b) Group inspection by members from other shops – weekly.

c) Stopping work in case of unsafe act/non-use of PPEs.

d) Letters to spouses for safety violations.

e) Strictness on safety clearance/permission to contractors.

Usha Beltron Limited

Usha Beltron Limited (UBL) a private Jhawars-owned alloy steel manufacturing unit at Adityapur near Jamshedpur. The unit produces mild/high carbon steel and low alloy steels. These steel are used for making wire rods and wire rope at its wire rope division at Ranchi.

Usha Beltron Limited produces special grades of wire such as stainless steel wires, needle wires and shaped wires for domestic markets and the customers engaged in Automobile production, Construction industry, Power industry, Railway equipments etc. Steel wires find its application in making of Auto Tyres, Springs and industrial fasteners.

Usha Beltron limited is the largest producer of wire ropes in the south and Southeast Asia. It is also among the top five manufactures of wire ropes worldwide. The wire ropes are used mainly in Mining, Oil exploration and Extraction, Bridge and other civil construction. Usha Beltron also provides the entire range of end-of-rope products like shackles and pulleys.

ENGINEERING INDUSTRIES

Heavy Engineering Corporation, Ranchi

M/s. Heavy Engineering Corporation Ltd. a fully owned Government of India Undertaking was incorporated in Bihar on 31-12-1958. Foundry Forge Plant (FFP) is one of the three plants, the other two being Heavy Machine Building Plant (HMBP) and the Heavy Machine Tool Plant (HMTP), all situated at one place under this corporate sector. FFP was initially setup to produce annually around 1.3 Lakh Ton of heavy castings and forgings. These capital items were to be routed through HMBP and HMTP to their final destination of building up one steel plant every year. FFP, therefore, was envisaged to be the main feeding unit for both HMBP and HMTP.

Foundry Forge Plant is one of the biggest industry of its kind in SE Asia. It is located at latitude 23º23’ North & longitude 85º23’ East in the South West of Ranchi. The location of the site was decided after careful consideration. It is centrally located with respect to its sister units. It is situated amidst a healthy industrial belt having access and proximity to natural sources of almost all kind of raw materials that it requires. It fits naturally on the ecological balance. A generally south- westerly wind, 200 cm average rainfall every year and a vast afforested area all around takes due care of any environmental abuses that the processes of the factory may produce. The temperature varies between 5ºC in winter and 42ºC in summer. Chotonagpur belt specially Ranchi had a complete turn around in the last 30 years in terms of literacy, employment and all round development after HEC came into existence.

This factory covers around 1,316,930 Sqm. area of which 2,85,020 Sqm. Is built up. Entire plant is divided into three belts. The first belt running centrally from east to west consists of basic manufacturing units such as pattern shop, Iron & Steel Foundries, Forge shop and the Rough machine shop. This main belt is flanked on either side by parallel subsidiary area. The area on the south contains all the Power and Engineering shops and other ancillary services so that various section of works get a favourable and balanced fuel and energy supply. Officers and amenities buildings for the staff and workers occupy the northern flank. The production and services area are well connected by inplant railway tracks and is connected to the outside via inplant marshaling yard and Hatia station so as to maintain uninterrupted flow of material and finished products. The internal track line runs to the length of 33 kms. A total of 16.5 km. length of road is laid which is as per requirement of heavy and light traffic.

Water requirement in the plant is met by 17M deep dam constructed on the river Subernrekha. Inside the plant, extensive pipeline system is laid out for drinking water. Three outlet 60ӯ RCC pipes have been provided for draining out storm water of the plant area. The sewerage system involves lying of more than 22 km of concrete pipe under the ground.

Electrical distribution system consists of 132 KV double overhead line with switching station of Gola. This 132 KV is stepped down to 33 KV at the entrance switching station at FFP where it is further coupled with 33 KV distribution system of the Bihar State Electricity Board. This has been to alternate facilities as per need. There are in all 18 intermediate transformer substation situated in the whole plant for individual tapping.

The individual production unit of the plant is almost as big as many of the large factories in the country. About 60,000T of machinery are installed in the plant. Some of the shops are 40M high with 80M high chimneys. A few of these carry large cranes of 200T capacity and big steel columns weighing 140T with steel base of 29 sq.meter. A special feature of this plant is the underground soaking furnaces, big ones measuring 20X14X25m. In this plant, castings and forgings of practically any type and composition from a few kg to as heavy as 100T piece weight are produced.

FFP was built with DPR production rating of 1,30,000T of iron & steel castings and steel forgings per annum principally for the building up of steel plants in India and later on elsewhere. The infrastructure was laid but production capacity was never attained due to conceptual error. Later on, it was conceded that India being a tropical country and an average Indian being lesser capable than the Europeans due to different food habits and the stamina, the maximum achievable capacity could be around 50,000T. This was the essence of the report submitted by the Fazal Committee in 1974. The maximum that was achieved was around 38,000T in 1976. Therefore, the layout, the facilities, the amenities already established did the statutes demand far superior than those. Pollution control measures developed for the DPR production wastes were never put to 100% efficiency l. A 30% production capacity utilization also means 3 times less waste and effluent generation.

PRODUCT mt/YEAR	DPR CAPACITY GROSS (MT)	ACHIEVABLE (FAZAL COMMITTEE)		MAXM. ACHIEVED (1975-76)		1997-98
		GROSSS	SALE	gROSS	SALE	DESPATCH	SALE
IRON STEEL FORGING	45995 46382 37457	15000 16200 20015	14080 15465 15035	14125 10017 13773	12725 9076 9909	99 3111 784	20500 175700 49600
TOTAL	129834	51215	44580	37915	31710	3994	245800

NOTE: Figures are in MT and Rs. Thousand

Table - 4

No. of workers employed during the year 2002-2005

	Year
	2002	2003	2004	2005
Regular Employees	2457	1605	1438	1361
Contract Labour	232	290	450	570

TATA MOTORS LTD, JAMSHEDPUR

Tata Motors Ltd. is one of the pioneers in automobile sector in the country on its path to World Class Manufacturing has incorporated environmentally sound practices as one of its prime objectives- in its process, products and services. It Aims to create a seamless organization that promotes innovation, excellence, as well as the Tata core values of integrity, customer focus, corporate citizenship and a “passion for engineering” Commitment to high standards of safety ,environment and health are also espoused in the Tata Code of Conduct fully integrated into the company’s operational philosophy and culture. Tata Motors’ mission is also to upgrade the quality of life of communities in and around the company’s operations.

National environmental regulation governing the automobile manufacturing industry continued to follow the stringent trend of the past. Emission and pass-by noise norms for products and disposal of hazardous wastes from manufacturing process are two significant areas. Deadlines for complying with European legislation governing re-cyclability of products are also drawing near.

This was the first unit of the Company established in 1945 and is spread over an area of 822 acres. It consists of 3 divisions - Truck, Engine (including the Gear Box division) and Axle. The divestments in March 2000 hived off the Axle and Engine plants into independent subsidiaries. The Truck Division boasts of two assembly lines. The main assembly line, measuring 180 metres in length, has 20 stations with a vehicle rolling out every 8 minutes while the other line is dedicated to Special Purpose Vehicles (SPVs). State-of-the-art facilities like a Centralized Paint and Press Shop with a set-up of a 5000 tons Siempelkamp press line and a cut-to-length line for strip preparation purchased from M/s. Kohler of Germany makes it a fairly advanced production outfit.

The number of workers employed in TATA Motors during the period 2002-04 is given below:

Table - 5

No. of workers employed

	Year
	2002	2003	2004
Regular Employees	9986	11107	10008
Contract Labour	500	500	500

This is supported by a fully equipped Foundry, which supplies high-grade SG Iron castings for automobile components and excavators and is rated as one of the cleaner, better and highly automated foundries in the world. The Foundry has a sophisticated Kunkel Wagner high pressure moulding line, which has a rated production capacity of 90 pairs of moulds every hour. The Foundry has its own melting shop, core shop and sand plant.

Other advanced facilities include Channel Furnaces, Computerized Testing Equipment etc. In 1993, the Foundry was ISO 9002 certified by the Bureau Of Veritas Quality International and later followed it up with the more stringent QS 9000 certification from the BVQI in the year 2000.

The unit is also equipped with a semi-automated forging line, with 40,000 mkg Beche hammer and state-of-the art presses from Kurimoto of Japan and is one of the most modern forging set-ups in the country. It produces critical forgings like crankshafts, front axle beams and steering parts for the automobile plant. The new forging line, installed on April 20, 1984, has the capability to forge front axle beams at 90 sec per piece and crankshafts at 120 sec per piece. Mechanical presses help produce a variety of heavy forgings. The sophisticated FIDIA Digit 165 CC graphite-milling machine links shop floor machines to the design workstation. The Forge has been certified as ISO 9002 and QS 9000 by the BVQI.

Central Tool Room, Jamshedpur

The Central Tool Room at Tata Motors, Jamshedpur is one of the most modern tool rooms in India. Equipped with the latest CNC Machines, Tryout Presses and Inspection facilities, this tool room has the proven capability of developing tooling solutions for all applications.