Success Story on LOTO Implementation

Old is Gold, saying to emphasize the value of old things, thoughts and other relevant, But is old Safety culture, thinking and system is Gold or worthy?

Change is Beautiful, saying to encourage new things and ideas, but are we favouring change? Are we accepting that Safety is our own responsibility or own social responsibility?

Safety at work and safe working environment are amongst the most valuable assets of individuals, communities and countries. In the view of swift industrial growth and progress in India, it becomes imperative that safety at workplace be given its due importance. However, with stress being laid on quick profits, safety aspects are generally ignored. We, at MP Birla Group being responsible corporate are giving utmost important to Health and Safety at workplace.

Founded in 1919, the M.P. Birla Group is amongst the largest industrial houses in India. The company leads the scene the in the cement industry with strong presence in northern, central and eastern India. Considered one of the leaders in cable industry, the M.P. Birla Group has joint ventures with global giants like Furukawa. The Company has acquired 100% shares of Reliance Cement Company Private Limited (RCCPL), a subsidiary of Reliance Infrastructure Limited, Anil Dhirubhai Ambani Group. This acquisition provides Birla Corporation Limited (BCL) with the ownership of high-quality assets, taking its total capacity of 15.5 MTPA.

Being a new establishment, Reliance Cement plant(s) were equipped with latest safety requirements in terms of equipment compatibility and system & technical standards. In other hand, there were lot of scope for improvement in Birla Corporation plants, established 5 to 6 decades ago.

One of the major challenge in safety system implementation was Lockout Tagout implementation as being very old plant equipment and electrical panels were not compatible or not having locking provision. Therefore, finally we have decided to go for Gap assessment study of complete LOTO system for holistic implementation.

We did comprehensive gap assessment from internal Safety team as well as domain expert agencies and derived short term and long-term improvement plans.

On hardware front, all panels / equipment were modified / replaced with Lockout arrangements, procured kits for energy isolation devices like electrical energy, mechanical energy. Extensive Trainings to all workers and employees on Lockout Tagout procedures and sensitization workshop for middle and senior management employees. Displays at conspicuous locations on Do’s & Don’ts and advantage of LOTO system.

Upon Implementing LOTO system, audit has been conducted for all plants to check the level of implementation and plan ahead. After successful implementation, we have converted our paper based permit system to complete digital permit (SAP based) with equipment and process interlocks.

Please refer attached diagram to understand complete LOTO journey

Ajay Tiwari,
Head – Corporate OHS
Birla Corporation Limited,
MP Birla Group,
Mumbai.