Journal of Industrial Safety Engineering vol 3 issue 3

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STM JOURNALS

1. Discomfort Analysis in Pneumatic Grinding: Steam Generator Manufacturing Industry
Mani Chidambaram, Sankaranarayanasamy Krishnasamy, Muthukumar Krishnamoorthy 1
2. Improvement of the Space Management of Any Organization Using Different Japanese Management Tool
Yash D. Shah, G.D. Acharya 11
3. Metallic Pollution Level in Soils of Mymensingh Town, Bangladesh: An Impact of Urbanization and
Industrialization
H.M. Zakir, Md. Sohrab Hossain 17
4. Optimization of MRR and TWR on Electro Discharge Machining using Taguchi based GRA
Shivani Yadav, Manoj Kumar Gaur, Sharad Agrawal 26
5. Optimization of Process Parameters in EDM Machine with AISI 304 Stainless Steel using TOPSIS
Gurjeet Kaur, Manoj Kumar Gaur 33
6. Energy Saving Measures in Industrial Production: A Case Study
Prashant Sharma, Waris Nawaz Khan 39
7. Recommendation on Personal Protective Equipment: Safety Review
C.B. Mohod 43
ContentsJournal of Industrial Safety Engineering

JoISE (2016) 1-10 © STM Journals 2016. All Rights Reserved Page 1
Volume 3, Issue 3
www.stmjournals.com
Discomfort Analysis in Pneumatic Grinding: Steam
Generator Manufacturing Industry
Mani Chidambaram1
, Sankaranarayanasamy Krishnasamy2
, Muthukumar
Krishnamoorthy3
1,2
Department of Mechanical Engineering, National Institute of Technology,
Tiruchirappalli, Tamil Nadu, India
3
Department of Safety Management, Bharat Heavy Electricals Ltd., Tiruchirappalli,
Tamil Nadu, India
Abstract
Steam generator manufacturing involves a lot of custom designed components requiring
intensive fabrication activities of welding and grinding. Pneumatic grinding machines of
different types are widely used in such industries as they offer flexibility and ease of use.
However, the deployment of pneumatic tools are associated with hand transmitted vibration
and related health issues. The present study aims to evaluate the extent of discomfort levels of
operators and its relationship with the grinding intensity and at various times of the day.
Pneumatic grinding operators involved in manufacturing steam generator components were
chosen and data was collected based on Corlett and Bishop’s body part discomfort mapping,
at various time intervals from starting to end of the shift, using a structured questionnaire.
ANOVA was deployed to carry out the statistical analysis. The grinding operators working in
‘drums and headers’ product group reported the maximum discomfort compared to operators
working in other product groups. The discomfort increases as the shift progresses and reaches
the highest at the end of the shift. The study also brought out that most operators reported
discomfort in ‘shoulder’ (93%), followed by wrist (85%), neck (70%), lower back (65%) and
forearm (61%). Apart from providing leather and anti-vibration protective gloves to the
grinding operators, the industry is working to reduce hand arm vibration problems by
experimenting with modified handles and lower weight grinders. In addition to that,
distributing the exposure of grinding operators amongst different product groups could bring
a balance in discomfort faced by them, by periodical job rotation.
Keywords: Discomfort mapping, hand arm vibration, pneumatic grinders, work-related
musculoskeletal disorders
INTRODUCTION
Major industries like construction, mining,
manufacturing, shipbuilding and aircraft
industry deploy powered hand tools despite
high level of automation. Because of ease of
use and flexibility, powered hand tools play a
vital role in aircraft industry. High exposure to
vibration occurs during use of a riveting
hammer. Tools like power screwdrivers, saws
and grinding machines are other hand tools
contributing to vibration exposure [1].
Deployment of powered hand tools gives the
triple benefit of productivity, quality and time
saving [2]. Intensive exposure to vibration
from powered hand tools for a prolonged time
may cause hand arm vibration syndrome
(HAVS) [3–8]. Hand transmitted vibration has
also been identified as a contributing factor in
the development of carpal tunnel syndrome
(CTS) [9].Operators having exposure to hand
transmitted vibration may either be affected
with vascular and/or neurological disorder
separately or together.
In Europe, one in three workers are exposed to
some type of vibration from the machines or
tools and the duration of exposure is at least 2
hours a day [10]. About 1.7 to 3.6 % of the
workers in USA and Europe run the risk of
exposure to potentially harmful hand
transmitted vibration. Workers with prolonged
exposure also complain of muscular weakness,
pain, lowering of handgrip strength and
muscle force [11]. Other health issues include

Volume 3, Issue 3
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Improvement of the Space Management of Any
Organization Using Different Japanese Management Tool
Yash D. Shah1,
*, G.D. Acharya2
1
Department of Mechanical Engineering, Atmiya Institute of Technology and Science, Rajkot,
Gujarat, India
2
Principal, Atmiya Institute of Technology and Science, Rajkot, Gujarat, India
Abstract
This paper will fully deal on the Kaizen formula and 5S of Japanese strategies for the
improvement in space management of several organizations. Global markets are continuously
changing and demanding product of high quality and low cost. Cottage industries play an
important role in Indian economy. There are large numbers of in industries and it is emerging
an as providing larger employment opportunities next to agriculture. Lean manufacturing is
one of the fundamental plans of action to achieve cost cutting using space management.
Products can be produced using lean manufacturing; perhaps for basic quality management
tool for cleaning for work place improvement, 5S and Kaizen are also used.
Keywords: Space management, quality control, Kaizen, 5S, TQM
INTRODUCTION
This paper aim is to produce an absolute study
between total quality management. Lean
Manufacturing system was started by the
Toyota production [1]. The lean
manufacturing includes TQM, originally
founded in the Japanese automotive industry;
also process of lean manufacturing was
generally carried out in the Western countries.
The paper systematically categorizes the
related literature of different survey, study the
literature and ultimately prospect it
methodologically [2].
The use of the term "Lean", in a business or
manufacturing geographic area, tells about a
philosophy that integrate a collection of tools
and techniques for optimizing time into the
business processes, and productivity, while
improving the quality level of products and
services to their customers [3]. The term
"Lean" is used in a business or manufacturing
environment, describes incorporates briefly in
a collection of different tools and techniques
into the enterprise processes and productivity,
instead of raising the quality selection level of
products and services to their customers [4].
There are two management approaches to
optimization they are: Total Quality
Management (TQM) and Lean Manufacturing
(LM). Total quality management (TQM) is
“The management of quality at all stage of
operations from planning and design through
self-inspection, to continual process
monitoring form provident opportunities” [5].
However, different definitions of TQM have
been presented over the years. Dale claims that
TQM is both a philosophy and a set of guiding
principles for managing an organization [6].
LM is the production of using less number of
goods. By Using LM with any company, the
goals would be to use less waste, less human
attempt, and less engineering to develop a new
product [7]. Lean principles are fundamentally
value driven for any customer, which makes
many manufacturing in appropriate manner
and distribution situations. Principles of LM
are generally acknowledged as show Figure 1.
Understanding customer value and what the
customers realize as value of its importance.
For understanding any Value for the
customers, the next step is to analyze the
business processes by adding values that any
ones actually need. The best Japanese
management practices is originated by the
Kaizen management and is dedicated to the
improvement of productivity, quality for

Volume 3, Issue 3
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Metallic Pollution Level in Soils of Mymensingh Town,
Bangladesh: An Impact of Urbanization and
Industrialization
H.M. Zakir*, Md. Sohrab Hossain
Department of Agricultural Chemistry, Faculty of Agriculture, Bangladesh Agricultural University,
Mymensingh, Bangladesh
Abstract
Untreated urban and industrial wastes disposal in Mymensingh town are the major problem
and responsible for soil and water pollution. Total 24 soil samples were collected from
different locations of Mymensingh town to assess metallic pollution level as well as to study
some other physicochemical properties of soils. The mean total concentrations of Cu, Zn, Pb,
Cd and Fe in soil samples were 68.69, 193.06, 62.47, trace and 18481.82 µg g-1
, respectively.
The present study revealed that the average Cu, Zn and Pb contents in soils were higher
compared with several other industrial areas in home and abroad as well as geochemical
background values of continental crust. Iron content in soils showed highly significant
positive relationship with Zn and Pb, which indicate that these metals were interrelated with
each other and may be originated from the same source to the study area. The calculated Igeo
for Pb, Zn and Cu exhibited positive values and Igeo class: 1–3, indicating moderately to
strongly polluted soil quality. Similarly, considering EFc, 100, 55 and 14% locations had EFc
values > 5.0 for Pb, Zn and Cu, respectively, which indicates anthropogenic enrichment of
these metals to the area.
Keywords: Metallic pollution, soil, industrialization, Bangladesh
INTRODUCTION
Soil and water, both the resources have been
subjected to severely degraded or polluted due
to urbanization and industrialization. The
pollution includes point sources such as
emission, effluents and solid discharge from
industries, vehicle exhaustion and metal from
smelting and mining, and nonpoint sources
such as soluble salts, use of agrochemicals,
disposal of industrial and municipal wastes
and others [1, 2]. Each source of
contamination has its own damaging effects to
plants, animals and ultimately to human
health, but those that add metals to the
environment are of serious concern due to
their persistence and carcinogenicity. They
cannot be destroyed biologically but are only
transformed from one oxidation state or
organic complex to another [3].
In Bangladesh, last few decades
industrialization is encouraged to engage a
huge volume of young forces to the economy
as well as to meet up the basic demand of the
population. As a result, there is a progressive
increase in industrial wastes, which causing
severe contamination to the air, water and
soils, thus polluting the environment. During
the last few years, a number of research works
has been reported severe metallic contamina-
tion to soil, water and sediments [4–9] in
different parts of the country. The same
scenario is also applicable for Mymensingh
town, which is highly susceptible to
environmental pollution due to over
population, rapid industrialization and
urbanization in last few years. A study
reported that total volume of waste generation
from different mills and industries of BSCIC
area of Mymensingh town is 9758 kg/day of
which 1223, 3115 and 5420 kg/day of wastes
are produced by the small, medium and large
category industries, respectively [10].
Considering the above facts, the present study
was planned to determine the concentration of
some toxic metals in soils of Mymensingh
town as well as to assess their contamination
level.

Volume 3, Issue 3
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Optimization of MRR and TWR on Electro Discharge
Machining using Taguchi based GRA
Shivani Yadav*, Manoj Kumar Gaur, Sharad Agrawal
Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior,
Madhya Pradesh, India
Abstract
Electro Discharge Machining (EDM) is one of the most effective nonconventional machining
processes in order to obtain better finishing quality result. It is vastly used to machine the
most complex as well as intricate shapes so as the productivity increases in a very short time
interval. The input parameters are; discharge current, voltage and pulse on time. Taguchi L9
orthogonal array is used to find out the Signal to Noise ratio by optimizing the performance
parameters based upon the input parameters. The performance parameters so optimize as
material removal rate, tool wear rate. Using the GREY RELATIONAL ANALYSIS, the
correlation has to be draw out that makes the optimized value very accurate.
Keywords: MRR, TWR, Grey Relational Analysis, Current, Pulse on time
INTRODUCTION
In order to improve the productivity,
continuous production is required without any
noise factor so as the better performance has to
be created. Electro Discharge Machining
(EDM) is a very beneficial machine in order to
machine the most intricate as well as
complicate shapes. It contains cathode as well
as the anode electrode. The tool electrode is
taken as negative terminal as well as the
workpiece is taken as the positive terminal.
When the positive electrons moved from the
workpiece towards the tool electrode, a plasma
channel is created between both the electrodes,
due to which the avalanche motion is created
by the electrons that thereafter created the
thermal conductivity so that spark is
generated. That is why it is called as Spark
Erosion Machine. For this, the tool electrode
should be having high thermal conductivity
and electrical conductivity.
The working principle of EDM is based on
thermoelectric energy. Hence, this is a type of
electrothermal process. Due to the less time
interval of the pulse on time, the heat
generated is very low. The heat affected zone
can be carried out to 2–4 µm of the spark
crater. Dielectric fluid is used to ionize the
electrons, it should be oxygen free.
Transformer oil is used as the dielectric fluid.
The tool material copper is used. Besides
having its high cost, it satisfies all the required
properties having high density, high thermal as
well as electrical conductivity. In this research
paper, the workpiece performance examined
by MRR and TWR by using the input
parameters.
LITERATURE REVIEW
Today the research on EDM is going to be
very important not only the area of technical
specifications but also on the aspect of
productivity. The main objective of this paper
is to investigate the performance of workpiece
based upon the input parameters. The
workpiece taken as AISI 202 SS. The EDM
machine used was TOOLCRAFT A50 EDM
SPARK EROSION MACHINE. The dielectric
medium is so taken to make oxygen free
machining process. It is taken as transformer
oil. The tool electrode is taken as negative
terminal and workpiece is taken as positive
terminal due to which the movement of free
electrons takes place from workpiece towards
tool. A spark is generated due to the formation
of plasma channel. The experimental data
carried upon by the Taguchi L9 orthogonal
array to identify the graphs relating to S/N
ratio. It is accompanied by the grey relational
analysis to make correlation between both the
factors. For MRR, “Large the better” is taken

Volume 3, Issue 3
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Optimization of Process Parameters in EDM Machine
with AISI 304 Stainless Steel using TOPSIS
Gurjeet Kaur*, Manoj Kumar Gaur
Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior,
Madhya Pradesh, India
Abstract
The effective solution based on TOPSIS approach to determine the optimal process
parameters in die sinking electrical discharge machining. Taguchi L9 orthogonal array is used
to gather information regarding the process with less number of experimental runs.
Experiments have been conducted using three process parameters such as peak current, gap
voltage, pulse on time, with three levels are selected to optimize the multiple objectives. AISI
304 stainless steel as a work-piece material and copper as electrode material used for the
experiments are arranged on the electrical discharge machine for the research work in order
to develop the optimal condition of the response parameters MRR and TWR.
Keywords: Response parameter (MMR, TWR), EDM, AISI 304, TOPSIS, ANOVA
INTRODUCTION
Die sinking Electrical Discharge Machining is
one of the earliest nontraditional machining
processes. EDM process is based on
thermoelectric energy in which electrical
energy is used to generate electrical spark and
material removal occurs due to thermal energy
produced by the spark. A pulse discharge
occurs in a small gap between the work-piece
and the electrode. Then fresh dielectric fluid
rushes in the gap, flushing away the debris and
quenching the surface of work-piece. The EDM
SPARK EROSION MACHINE TOOLCRAFT
A50 spark generator used for the experiments
which is having a maximum current capacity of
50A and maximum allowance is 0.1 mm.
Today variety of industries require materials
that are highly temperature resistant and
provide higher strength, toughness, highly
resistant to corrosion and other properties
therefore, it has become essential to have such
process that are safe and conveniently
machined the hardened materials with accuracy
hence nonconventional machines are preferred.
For machining of hardened steel, the preferred
metal cutting process is electrical discharge
machining. This process is characterized by
good material removal rate, better dimensional
accuracy and good surface finish [1]. This study
presents a methodology for evaluation and
ranking by TOPSIS approach along with
Taguchi orthogonal array [2]. The experimental
analysis using the proposed approach gave the
optimized and profitable result. The overall
analysis of the process parameters is done by
statistical ANOVA approach in MINITAB 17.0
to have accurate results [3].
LITERATURE REVIEW
To establish a relation between input
parameters and output parameters various
approaches like empirical relation, nonlinear
regression, response surface methodology,
fuzzy-logic, VIKOR, TOPSIS, etc. Now we
have considered here TOPSIS, simple additive
weighting [4]. Supported case study shows the
effective use of methodology in a (EDM)
nontraditional manufacturing processes. The
proposed models used peak current, gap
voltage, pulse on time, and pulse off time as
input parameters. The predictions based on the
above developed models were verified with
another set of experiments and were found to
be in good agreement with the experimental
results. All theoretical statements are
illustrated by numerous examples and
calculations. Rao et al. aimed at optimizing the
hardness of surface produced in die sinking
electric discharge machining (EDM) by
considering the simultaneous effect of various
input parameters [5, 6]. It was observed that
type of material effectively influences the

Volume 3, Issue 3
www.stmjournals.com
Energy Saving Measures in Industrial
Production: A Case Study
Prashant Sharma*, Waris Nawaz Khan
Department of Mechanical Engineering, Noida International University, Noida,
Uttar Pradesh, India
Abstract
The energy efficiency project for the industries will improve energy efficiency in public and
social facilities and enabling environment for sustainable energy financing. The primary and
secondary aim of this paper is to save energy that will results in economical environment
friendly production practices. This paper proposes ideas that how energy saving can be
executed in industries by the application energy saving products. Case studies have been
carried out to bring out the quantitative data for the comparison, analysis and decision
making regarding implementation. The paper tries to convert the energy saving into the
monetary value to showcase the actual impact of suggestive measures on the production
economy. The end results show 54% savings to investment ratio with a payback period of 137
days.
Keywords: Energy, efficiency, savings, production economy
INTRODUCTION
Energy is the primary source that is only
responsible for doing any work in the day-to-
day life or in the plants. Energy is being
produced by many ways then it is utilized in
many ways. The industrial sector alone
accounts for about 50% of the commercial
energy. It uses both, the thermal and electrical
energy in various equipment like boilers,
compressors, furnaces, diesel generating
engines, motors, pumps, refrigeration, etc.
Here are tips for energy saving through these
equipment. The main objectives of saving
energy are as follows to protect the global
environment, energy-saving laws, ISO14000
compliant (corporate social responsibility),
reduce production costs (more profits for
companies).
Types of Energies Used in the Industries
Electrical Energy: General
The industrial sector consumes about 33% of
the total electrical energy consumed in the
country.
Compressed Air
It is the air more than the atmospheric pressure
i.e. 1 bar. Compressed air is a major source of
energy used in the industries and is responsible
for major applications such as pneumatic tools,
cleaning purpose, vacuum applications,
suction etc. It is preferred in industries because
of its convenience and safety and easy
availability.
Cooling Towers
It is a type of specialized heat exchanger in
which air and water are placed into direct
contact together for the transfer of heat. It is a
tall, cylindrical concrete tower, open-topped
used for cooling water or condensing steam
from an industrial process. It is used for
providing cooled water for air-conditioning,
manufacturing and electric power generation.
Electric Motors
The electric motors are used to provide motive
power to equipment such as compressors,
pumps, blowers, etc. It is important that the
industrial users define their need accurately to
enable proper selection of a motor for a
particular application. Of the total electricity
consumed in the industrial sector, electric
motors account for approximately 70%.
Lighting
A lumen is the measurement of light output
from a lamp, often called a tube or a bulb. All

Volume 3, Issue 3
www.stmjournals.com
Recommendation on Personal Protective
Equipment: Safety Review
C.B. Mohod*
Department of Chemical Engineering, Government Polytechnic, Arvi, Wardha, Maharashtra, India
Abstract
Personal protective equipment are used to avoid contaminated exposure. The risks of hazards
depend upon concentration of hazardous chemicals at work place. So, protective equipment
are always used to guard human body parts. This review paper has recommended safety
guidelines in present discussion. These guidelines are surveyed to adopt safety precautions at
work environment for all users, while this paper has also included procedure to use
respiratory and non-respiratory protection for health safety against dangerous environment.
Keywords: Respiratory, personal clothing, safety
INTRODUCTION
Personal protective equipment (PPE) includes
all clothing and work accessories projected to
protect user from workplace hazards in many
working industries like explosive,
petrochemical, chemical industry and sensitive
industries like food, dairy industry, and
pharmaceutical industry.
In industry, it is mandatory to wear personal
protective equipment as required, while
entering a campus of an industry or research
laboratory etc. Personal protective
equipment’s are used to prevent exposure and
contamination. Dangerous chemicals are often
used and handled at workplaces. The risk of
injury or ill health depends upon exposure to
the hazards of the chemicals at work place.
Therefore, personal protective equipment
(PPE) is one of the safety measures in point of
accidents or injury. PPE is referred as
equipment that is proposed to be worn or used
by a person at work place and that protects the
person against one or more risks arising from
chemical or physical operation to the person’s
safety or health.
Training helps user in acquiring the necessary
attitude, knowledge and skills in order to be
experienced in using PPE for handling and use
of chemicals. PPE is widely accepted and used
by employers for the beneficiary of a user.
Users often demand safety equipment for their
safety at workplace.
LITERATURE REVIEW
Spectacles containing reflective metallic
coatings and materials that filter out infrared
are the ideal means, while aluminium and
inconel (and alloy of iron, nickel and
chromium) provide excellent infrared
reflectance [1]. The main difficulty with using
reflective metallic coatings is that they are
susceptible to scratching, abrasions and other
faults that cause the breakdown of the coating.
American Optical (‘Pfund’s glass’), in which a
gold layer reflects 96% of infrared while
transmitting 75% of visible light. The metal is
sandwiched between clear optical crown glass
and crookes a glass, which absorbs 100% of
ultraviolet [1].
Corrective eyeglasses worn by users lift up a
problem when fitting respirators, while special
mountings are available to hold corrective
lenses inside full face pieces provide good
vision, comfort, and proper sealing. Latex can
cause allergic skin responses, while wearing
latex gloves. Radio frequency (RF), the most
apparent biological effects of RF energy to
living cells are due to heating [2].
Respiratory and facial protection is required
for those organisms that are usually
transmitted via the droplet/airborne route, or

Journal of Industrial Safety Engineering vol 3 issue 3

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