In a significant step toward enhancing workplace safety, the TEJAS Safety Circle of SAIL, Rourkela Steel Plant (RSP) has successfully executed a critical project to mitigate hazards caused by hot flying scales from the primary descaler of the New Plate Mill (NPM). The initiative, underscores the commitment of the plant to promote a culture of proactive safety, innovation, and operational excellence.

The five-member TEJAS team comprising Mr. Deepak Sahu, Engineering Associate, Mr. Gopabandhu Behera, Mr. Shirshananda Das and Ms. Supriya Bhoi, all Junior Engineering Associates along with facilitator Mr. Abhijit Patnayak, Senior Manager (NPM) carried out a detailed safety audit in the descaling zone. During their inspection, the team identified over 100 unsafe conditions and acts, related to the hazard of hot flying scales. This particular hazard had the potential to cause serious injuries, fire incidents, and significant equipment damage.

Using the DIMAC (Define, Measure, Analyze, Improve, Control) methodology, the team conducted an in-depth root cause analysis. The investigation revealed key vulnerabilities. To address these challenges, the team implemented a robust and multi-faceted action plan that included installation of multi-layer chain curtains to contain flying scales, Fire insulation of exposed cables and motor areas, Protective shields for essential equipment, and Deployment of visual caution signage to enhance hazard awareness.

Following the implementation, there has been a substantial improvement in workplace safety. The initiative not only prevented potential production losses valued at over Rs. 1.56 crores but also led to a monthly saving of 24 man-hours. More importantly, it contributed to a stronger culture of safety, morale, and teamwork among employees.

The team Tejas presented the innovative project at the 16th Integrated Safety Circle Convention at SAIL, Bhilai Steel Plant and bagged the Gold medal for the project.