CONFIDENTIAL — Prepared exclusively for Kirloskar Ferrous Industries Limited · Interactive Digital Assessment
Digital companion. This interactive assessment accompanies PSC’s formal Hand Exposure Assessment & Engineering Control Recommendations. The issued PDF is the controlled technical document; this hosted version is provided for easier navigation, photographic review and continued use of the Find The Hand™ methodology.
KFIL × PSC HAND SAFETY
Hand Exposure Assessment · 16–17 September 2026

Find the hand.
Engineer the hand out of the hazard.

Engineering control recommendations for Kirloskar Ferrous Industries Limited across Nagar, Baramati and Jejuri.

THE HUMAN HAND IS NOT A TOOL™
2Assessment days
3KFIL locations
47Recorded observations
70+Photos & videos captured
5–8Recommended pilot applications
Assessment basis

47 observations. One repeatable engineering method.

PSC Hand Safety India conducted the two-day assessment across KFIL operations at Nagar, Baramati and Jejuri on 16–17 September 2026.

The purpose was to identify routine activities in which the human hand becomes part of the mechanical process, then examine whether that function can be eliminated, mechanised, fixtured, guarded, remotely controlled or transferred to an engineered interface.

Assessment question: Why does the hand need to be there?

Evidence & limitations

Evidence base: 47 recorded observations and more than 70 photographs/videos. Selected images are shown here as representative evidence.

Important: photographs do not establish load weight, temperature, frequency, equipment rating, sling certification, force or injury history. These must be confirmed by KFIL where required for engineering selection.

Priority: qualitative implementation priority, not a numerical risk score.

PSC demonstrations: tools visible in demonstration photographs were brought to site for assessment trials and are not evidence of existing KFIL implementation.

Executive assessment

The recurring issue is not a lack of PPE. It is the hand becoming part of the process.

Across the three locations, mechanical equipment performs much of the heavy movement, yet human hands repeatedly complete the final control function: guiding, steadying, pushing, pulling, rotating, aligning, retrieving, slinging, holding or positioning.

Principal opportunity: create a repeatable KFIL system for identifying where the hand enters routine work, understanding the function it performs, and removing or relocating that function through elimination, mechanisation, fixtures, guards, remote control or an engineered interface.

21

Nagar observations. Tubular handling, load guiding, striking, hot material, roll positioning and final alignment recur.

13

Baramati observations. Sling retrieval, tube handling, hydro-machine positioning, die/roll guidance and material handling stand out.

13

Jejuri observations. Billets, rolls, striking, hot material, improvised retrieval and open-yard load control are prominent.

PSC methodology

Find The Hand™

Before asking how to protect the hand, ask a different question: Why does the hand need to be there?

A photograph of ordinary work can become an engineering diagnostic. Locate every hand, identify the mechanical verb that describes what it is doing, identify what can move or release energy, then ask what could perform the same function without the hand occupying that position.

Observe
Watch the real task, not a staged demonstration.
Find the hand
Mark where hands enter the process.
Name the function
Guide, hold, push, pull, rotate, align, retrieve, separate, position.
Identify energy
Move, fall, swing, roll, close, release, strike, heat, recoil.
Engineer separation
Eliminate, mechanise, fixture, guard, remote or interface.
The correct engineering control begins with the function — not the product.
The Last 300 mm Rule™

Where mechanical control often becomes human precision.

Many tasks appear controlled through most of their travel. The crane, roller, hydraulic system or machine performs the movement. As the component approaches its final position, precision increases and the hand enters to complete the last adjustment.

The Last 300 mm Rule™ is an observation lens, not a universal safe-distance measurement. It directs attention to final approach, landing, seating, insertion, orientation and alignment — the points at which human intervention can increase just as clearances decrease.

Final placement: direct hand contact is used during the last stage of positioning — a classic Last 300 mm review point.
Final placement: direct hand contact is used during the last stage of positioning — a classic Last 300 mm review point.
From hazard identification to function identification

Do not only identify the hazard. Identify the function.

“Hand near suspended load” is an observation. It is not yet an engineering solution.

The next question is why the worker is touching the load. The hand may be stopping rotation, preventing lateral movement, aligning the bundle with supports, orienting it or completing final positioning. Each function can require a different control.

The same applies to sling retrieval, tubular handling and machine positioning. The strongest control may be a sequence change, fixture or machine modification rather than a hand tool.

HAND NEAR LOADWhat movement is being controlled, and during which phase?
HAND UNDER / AROUND MATERIALWhat must be retrieved, fed, captured or positioned?
HAND ON TUBERoll, rotate, push, pull, separate, guide or align?
HAND AT FINAL POSITIONWhat stops the mechanical system from completing the last movement?
The correct engineering control begins with the function — not the product.
The Hand Exposure Hierarchy™

Engineering before equipment.

The objective is not to replace every hand interaction with a hand tool. KFIL should first ask whether the hand entry can be eliminated or the function engineered out.

1Eliminate the hand entryCan the process be changed so intervention is unnecessary?
2Mechanise the functionCan rotation, alignment, retrieval, positioning or movement be performed mechanically?
3Fixture the workCan stops, guides, locating features, clamps or rollers control the component?
4Remote the interfaceIf human input remains necessary, can it be applied from a safer position?
5Standardise the methodProcedures, training, supervision and point-of-use placement sustain the engineered control.
6Protect residual exposurePPE remains important, but it does not remove the hand from a crush point or closing gap.
Photographic evidence

Direct control → improvised separation → engineered separation

The photographic record is most useful when read as a progression. Workers are not simply “doing something wrong”; they are trying to perform necessary mechanical functions. In several tasks, the shop floor has already created distance using rods, hooks or bars. That is evidence of an unmet engineering need.

01 · Current method
Pipe-bundle control without a dedicated remote load-control interface.
Pipe-bundle control without a dedicated remote load-control interface.
02 · Local separation
An improvised rebar extends reach — useful evidence that separation is already recognised as desirable.
An improvised rebar extends reach — useful evidence that separation is already recognised as desirable.
03 · Assessment demonstration
PSC demonstration during the assessment: a purpose-designed interface is trialled to move the hand away from the suspended load.
PSC demonstration during the assessment: a purpose-designed interface is trialled to move the hand away from the suspended load.
Important: PSC tools visible in assessment photographs were demonstration tools brought to site for trials. They are not evidence that KFIL's previously purchased PSC tools were already implemented in these operations.
Improvised tools · a critical finding

The improvised tool is not the end of the analysis. It is the beginning.

Several KFIL activities show locally fabricated rods, hooks, rebars or crowbar-type interfaces. The useful engineering interpretation is that the shop floor has already recognised that the hand should be farther away.

The problem is not necessarily the principle. The problem is that the interface may not have been engineered.

Distance alone does not make a tool safe.

An improvised device may increase reach but still require review of engagement, strength, grip, failure mode and operator position.

ReachEngagement geometryPush / pull controlMaterialGripStrengthFailure modeErgonomicsRepeatabilityInspection & storageThermal suitabilityWorking position

Do not remove a local solution until its function is understood.

If an improvised hook is simply confiscated, the task that caused the worker to create it still exists. The worker may return to direct hand contact. Treat recurring improvised devices as engineering clues: photograph the use, identify the function, determine movement and force, review geometry and environment, then decide whether to eliminate, mechanise, fixture or engineer the interface.

IMPROVISED TOOL→UNDERSTAND FUNCTION→REVIEW PROCESS→ENGINEER CONTROL→VALIDATE→STANDARDISE
Improvised tools

The improvised tool is not the end of the analysis. It is the beginning.

A locally fabricated rod, hook or crowbar often answers one immediate question: “How can I reach this without putting my hand there?” That instinct is valuable. But distance alone does not make an interface engineered.

What must be reviewed

Reach · engagement geometry · push/pull control · material · grip · strength · failure mode · ergonomics · repeatability · inspection · storage · environmental and thermal suitability.

Simply confiscating an improvised device can drive the worker back to direct hand contact while leaving the original task unchanged.

Recommended progression: improvised tool → understand the function → review the process → engineer the control → validate with operators → standardise.
Locally improvised extended interface: treat it as evidence of the required function and desired separation.
Locally improvised extended interface: treat it as evidence of the required function and desired separation.
Improvised devices need review of engagement, strength, grip, failure mode and repeatability before they can become a standard method.
Improvised devices need review of engagement, strength, grip, failure mode and repeatability before they can become a standard method.
Plant findings

Nagar · 21 observations

The strongest recurring theme at Nagar is tubular material: rotation, guiding, positioning, shifting, straightening and final placement. Suspended-load control, striking, hot material and roll positioning require separate control families rather than a single generic “hands-off tool”.

Direct hand force is used to rotate tubular material. The engineering question is the required movement: roll, rotate, push, pull, separate or align?
Direct hand force is used to rotate tubular material. The engineering question is the required movement: roll, rotate, push, pull, separate or align?
A bar is already being used as an extended interface for tube rotation — an opportunity to standardise geometry and method.
A bar is already being used as an extended interface for tube rotation — an opportunity to standardise geometry and method.
Direct hand contact around tubular material illustrates repeated hand intervention in routine process control.
Direct hand contact around tubular material illustrates repeated hand intervention in routine process control.

Recommended Nagar pilot focus

Tube rotation; supported and suspended tube guiding; long-tube movement; sling/rigging interaction; striking; and selected Assal Mill applications. Red-hot material and roll positioning should prioritise mechanisation, fixtures or remote handling rather than defaulting to a hand tool.

Plant findings

Baramati · 13 observations

Baramati presents particularly valuable opportunities around sling placement/retrieval and machine-interface positioning. If a hand enters only to hook, pull, capture or retrieve rigging, that function is an obvious candidate for remote handling.

Slinging can place the hand inside a bundle where access is constrained.
Slinging can place the hand inside a bundle where access is constrained.
Hand intervention beneath/alongside bundled material to move rigging is a high-value retrieval problem to engineer out.
Hand intervention beneath/alongside bundled material to move rigging is a high-value retrieval problem to engineer out.
Rigging sequence should be studied from preparation through de-rigging, not only at the moment of lift.
Rigging sequence should be studied from preparation through de-rigging, not only at the moment of lift.
For sling retrieval, first review whether the sequence can be changed or rigging pre-positioned. If manual retrieval remains necessary, trial a dedicated retrieval interface such as PSC Talon or another suitable method only after application validation.
Plant findings

Jejuri · 13 observations

Jejuri broadens the picture: billets, rolls, striking, hot material, retrieval and open-yard loading demonstrate that Find The Hand™ is not merely a suspended-load programme.

Extended rod used during a process operation: identify the exact function, forces, environment and thermal conditions before standardising a control.
Extended rod used during a process operation: identify the exact function, forces, environment and thermal conditions before standardising a control.
Direct holding of round material can place the hand close to movement and stored-energy interfaces.
Direct holding of round material can place the hand close to movement and stored-energy interfaces.
Access and worker position can be part of the engineering problem; some tasks require redesign beyond hand tools.
Access and worker position can be part of the engineering problem; some tasks require redesign beyond hand tools.

Number punching, scale cleaning and chipping should be reviewed for fixtures/holders or suitable extended striking interfaces. Red-hot billet movement should prioritise mechanisation or remote handling. Open-yard loading requires an integrated review of access, fall exposure, load control and worker position.

What the 47 observations tell us

Repetition is more important than any single photograph.

The significance of the evidence is the recurrence of similar hand functions across different plants and operations. KFIL can solve families of exposure rather than treating every photograph as an isolated safety issue.

10Suspended / crane-handled load control
12Tubular handling
2Sling placement & retrieval
4Striking / impact
4Hot material / hot process
7Roll, die & machine positioning
3Improvised retrieval / pulling
5Manual handling, access & other line-of-fire

Grouping follows the assessment register's control-family logic. Priorities are qualitative implementation priorities.

Engineering control families

Do not solve 47 photographs with 47 products.

The observations cluster into recurring mechanical functions. KFIL can solve families of exposure by engineering the function rather than treating every photograph as an isolated safety issue.

Exposure familyQuestion to answerPreferred engineering direction
Suspended-load controlWhat movement needs control and from where can the worker safely influence it?Lift-plan changes, taglines, push/pull interfaces, magnetic control where appropriate, defined worker position.
Tubular handlingRoll, rotate, push, pull, separate, guide or align?Mechanised rotation, guides/stops, tubular heads/interfaces, remote push/pull depending on function.
Sling placement & retrievalWhy must the hand enter beneath/around the material?Sequence change, pre-positioning, dedicated remote retrieval.
StrikingWhy must fingers hold the struck item?Fixture/holder first; extended holder such as FingerSaver where geometry fits.
Hot materialCan human proximity be removed?Mechanisation, remote manipulation, guarding and thermal separation.
Roll/die/machine positioningWhy does mechanical movement stop before final location?Stops, guides, fixtures, locating features, controlled mechanical positioning.
Suspended loads

The hand should not be the load-control system.

Direct hand intervention during suspended-load control. The hand is being used as the interface for guiding or steadying the load.
Direct hand intervention during suspended-load control. The hand is being used as the interface for guiding or steadying the load.
Direct hand contact during crane-load handling creates an opportunity to evaluate remote load-control methods and worker positioning.
Direct hand contact during crane-load handling creates an opportunity to evaluate remote load-control methods and worker positioning.

A remote interface does not make it acceptable to stand beneath a suspended load or within a closing gap. The interface is a control method, not permission to enter the line of fire.

Demonstration during assessment

Trial the function before standardising the tool.

PSC demonstration during assessment: magnetic positioning interface trial on ferrous material.
PSC demonstration during assessment: magnetic positioning interface trial on ferrous material.
PSC tool trial during site assessment. Suitability must be validated for the actual material, geometry, force, surface and task.
PSC tool trial during site assessment. Suitability must be validated for the actual material, geometry, force, surface and task.

The correct sequence is application → hand function → engineering options → controlled operator trial → modification if required → approved method → SOP/JSA → point-of-use placement → follow-up. Procurement alone does not create implementation.

From procurement to implementation

A safety tool does not become a safety system merely because it is present at site.

KFIL had previously procured limited quantities of PSC LoadGuider®, PSC FingerSaver® and PSC Load-It® Magnetic Tools. These were not observed as established, standardised controls across the applications reviewed during this assessment.

The next phase should therefore focus on application-led trials, operator validation and integration into the work method rather than broad tool procurement.

From assessment to implementation. This digital report reflects PSC’s completed hand-exposure assessment and recommended control directions. Where mechanisation, fixtures, machine-interface changes or purpose-designed devices are recommended, dimensions, detailed design and validation are implementation activities established against actual KFIL operating parameters.
SELECT APPLICATION→OBSERVE COMPLETE TASK→IDENTIFY HAND FUNCTION→SELECT / ENGINEER CONTROL→OPERATOR TRIAL→MODIFY→APPROVE METHOD→SOP / JSA→POINT-OF-USE→30–60 DAY VERIFY

Changing normalised hand intervention

When an activity is repeated without an immediate adverse outcome, direct hand intervention can gradually become part of the accepted method. Workers stop seeing “I am putting my hand into the process” and see “this is how the job is done.”

Change the process, not only the message

If the task still requires alignment, retrieval, rotation, positioning or guidance, the worker still needs a way to perform that function. The safer method must become the available, validated, expected and supervised method.

KFIL self-assessment

KFIL does not need PSC present to find the next 47 exposures.

Find The Hand™ can become a simple internal photographic assessment method used by supervisors, EHS teams and engineers during ordinary work.

Take one real photo
Capture worker, load, equipment, hands and available space.
Circle every hand
Where does it enter the process?
Write one verb
Guide / hold / push / pull / rotate / align / retrieve / separate / position.
Ask what can move
Fall / swing / roll / close / release / strike / heat / recoil.
Replace the function
Eliminate / mechanise / fixture / guard / remote / engineered interface.
The five-minute question: “What would perform the same function without the hand being there?” The answer should not automatically be a PSC product.
Make this a living KFIL Hand Exposure Register. For each new photograph record: plant, area, activity, where the hand enters, one mechanical verb for the hand function, what can move or release energy, current method, engineering opportunity, owner, status and verification date.
Implementation system

From tool purchase to tool implementation

KFIL previously purchased limited quantities of PSC LoadGuider®, PSC FingerSaver® and PSC Load-It® Magnetic Tools. The next stage should be application-led implementation rather than another broad procurement exercise.

Select application
Choose a repetitive exposure with a clear hand function.
Observe complete task
Include setup, movement, landing and retrieval.
Trial control
Involve operators and modify where necessary.
Standardise
SOP/JSA, training, point-of-use storage and supervision.
Verify 30–60 days
Repeat photography and confirm the method remains in use.
Master observation register

47 recorded observations

Use the filters to explore the assessment digitally. Priority is qualitative and intended to guide implementation focus, not to substitute for KFIL's formal risk-assessment system.

01
Nagar · Bay 6 · High

Tube Rotation

Hands used to rotate tubes to create space between bars/tubes.

PSC recommended control — Mechanise rotation or validate a purpose-designed tubular rotation interface.

02
Nagar · Bay 6 · High

Guiding & Positioning Tubes

Employees push/pull loads by hand to manipulate and position the job.

PSC recommended control — Separate suspended and supported tasks; trial suitable remote push/pull or tubular-control methods.

03
Nagar · Bay 6 · High

Loading – Guiding & Positioning

Direct contact is used to control and position material during loading.

PSC recommended control — Remote load control for landing and positioning; final method to be selected to suit the actual load geometry during implementation.

04
Nagar · Bay 6 · High

Long Tube Handling

Workers may remain within the movement envelope while guiding long tubes.

PSC recommended control — Define exclusion position and engineer remote directional control.

05
Nagar · Bay 6 · Medium

Strapping Tube Bundles

Hands enter close to bundle edges during strapping.

PSC recommended control — Review strapping sequence, access and extended placement/retrieval aids.

06
Nagar · Bay 6 · Medium

Checking Tube Thickness

Tube is manually rotated for inspection.

PSC recommended control — Provide controlled rotation method suited to inspection.

07
Nagar · Mill Finisher · High

Guiding & Positioning During Loading

Direct push/pull contact is used during positioning.

PSC recommended control — Engineer separation for final positioning.

08
Nagar · Mill Finisher · High

Handling Long Jobs

Workers can be within the movement path of long material.

PSC recommended control — Keep personnel outside the movement path and use an appropriate remote control method.

09
Nagar · Bay 4 · High

Load Guiding

Loads are guided by direct touch or locally improvised devices.

PSC recommended control — Retain the separation principle and replace the improvised method with a purpose-designed guiding interface.

10
Nagar · Bay 4 · High

Dipping Tubes in Hot Water / Tanks

Manual push/pull is performed close to tanks.

PSC recommended control — Prioritise mechanisation, remote manipulation and thermal separation.

11
Nagar · Bay 4 · High

180° Tube Rotation

Manual intervention is used to rotate tubes.

PSC recommended control — Engineer controlled rotation rather than direct hand force.

12
Nagar · Bay 4 · High

Hollow Conditioning

Load is pulled toward the operator.

PSC recommended control — Change the pull direction/operator position and use a purpose-designed remote interface.

13
Nagar · Bay 4 · High

Punching

A hand holds the tool while impact energy is applied.

PSC recommended control — Fixture/holder first; FingerSaver-type interface only where geometry is suitable.

14
Nagar · Bay 4 · High

Precise Positioning

Hands/feet enter the final positioning zone.

PSC recommended control — Remove direct hand/foot positioning using stops, guides, fixtures or a suitable remote interface.

15
Nagar · Bay 4 · Medium

Draw Bench Machine

Manual or improvised tube pulling is used.

PSC recommended control — Define required pulling function and engineer a repeatable interface.

16
Nagar · Assal Mill · High

Roll Positioning on Stand

Hands/body force are used for roll positioning.

PSC recommended control — Prioritise fixture/mechanical positioning; do not default to a hand tool.

17
Nagar · Assal Mill · High

Lifting Red-Hot Tubes

Manual intervention occurs around hot material.

PSC recommended control — Mechanisation or remote handling is the preferred control family.

18
Nagar · Assal Mill · High

Guiding & Positioning Tubes

Hands manipulate tubes during positioning.

PSC recommended control — Validate tubular-control interface after task study.

19
Nagar · Assal Mill · High

Shifting Bin Bucket

Hands are used to guide the bucket.

PSC recommended control — Remote load control and worker-position review.

20
Nagar · Bay 1/2 · High

Shifting Tubes

Hands control material movement.

PSC recommended control — Engineer separation based on required push/pull/rotation function.

21
Nagar · Bay 1/2 · High

Tube Straightening

Hands or improvised hooks pull/guide material toward the employee.

PSC recommended control — Redesign direction and validate purpose-built interface.

22
Baramati · Billet Yard · High

Guiding & Positioning Billet

Worker enters the load-control zone during crane-assisted positioning.

PSC recommended control — Remote control method plus exclusion position.

23
Baramati · EFS Warehouse · High

Rotating Tube

Large tube is rotated by hand.

PSC recommended control — Controlled tubular rotation interface or mechanisation.

24
Baramati · EFS Warehouse · High

Retrieving Slings

Hands approach/enter beneath material to retrieve rigging.

PSC recommended control — Change rigging sequence or use dedicated remote sling-retrieval interface.

25
Baramati · EFS Warehouse · High

Guiding Bundles During Loading

Bundles are manually guided.

PSC recommended control — Remote suspended-load control.

26
Baramati · EFS Warehouse · High

Positioning Load on Hydro Machine

Hands position material at the machine interface.

PSC recommended control — Fixture, guide or controlled final-positioning method.

27
Baramati · Tube Bay · High

Guiding Tubes

Hands or improvised devices are used to guide tubes.

PSC recommended control — Standardise a validated tubular interface.

28
Baramati · Tube Bay CNC · High

Retrieving Sling

Hands enter close to material to retrieve rigging.

PSC recommended control — Remote retrieval pilot.

29
Baramati · Finishing Area · High

Tube Stacking

Load is touched to achieve final stack position.

PSC recommended control — Last 300 mm review; stops/guides/remote interface.

30
Baramati · PQF Finishing · High

Guiding Tubes

Tube is pushed/pulled by hand.

PSC recommended control — Engineer push/pull separation.

31
Baramati · Cold Mill · High

Guiding Dies

Dies are manually pushed/pulled.

PSC recommended control — Fixture/mechanical guide preferred.

32
Baramati · Cold Mill · High

Roll Positioning

Direct touch is used during final positioning.

PSC recommended control — Mechanised or fixtured final positioning.

33
Baramati · Cold Mill · Medium

Gas Cylinder Handling

Manual handling creates struck-by/handling exposure.

PSC recommended control — Use approved cylinder material-handling control; treat separately from hands-off load tools.

34
Baramati · Cold Mill · Medium

Manual Scrap / Sample Tube Handling

Material is manually lifted.

PSC recommended control — Use an appropriate lift-assist or mechanical handling aid, selected to the actual weight, frequency and workstation arrangement.

35
Jejuri · SMS Mechanical Maintenance · High

Guiding Jumbo Bag

Bag is pushed/pulled during movement.

PSC recommended control — Remote load control appropriate to flexible load behaviour.

36
Jejuri · CCM · High

Guiding Cut Billet

An improvised hook is used to guide material.

PSC recommended control — Retain separation and replace the improvised hook with a purpose-designed, inspected remote interface suited to actual reach, temperature and engagement.

37
Jejuri · CCM · High

Moving Red-Hot Billet

Manual intervention occurs around red-hot material.

PSC recommended control — Mechanisation/remote handling before manual stand-off tools.

38
Jejuri · AQ · High

Billet Loading

Hands push/pull material.

PSC recommended control — Engineer remote push/pull or mechanical positioning.

39
Jejuri · AQ · Medium

Retrieving Change Link

Improvised retrieval method is used.

PSC recommended control — Engineer a dedicated retrieval interface.

40
Jejuri · Nagar Point · High

Pulling Bars

A hook is used to pull bars.

PSC recommended control — Position the operator outside the movement path and use a purpose-designed pulling interface with suitable engagement geometry.

41
Jejuri · Roll Shop · High

Guiding Rolls

Hands guide rolls.

PSC recommended control — Mechanical/fixtured guidance preferred.

42
Jejuri · Roll Shop · High

Positioning Roll Stand in Machine

Hands enter during precise positioning.

PSC recommended control — Use mechanised or fixture-based final positioning; establish the final arrangement to actual roll-stand and machine geometry during implementation.

43
Jejuri · Roll Shop · High

Number Punching

Fingers hold punches during striking.

PSC recommended control — Fixture/holder or suitable extended striking interface.

44
Jejuri · Roll Shop · High

Scale Cleaning

Hand holds chisel during striking.

PSC recommended control — Fixture/holder or suitable extended striking interface.

45
Jejuri · Roll Shop · High

Chipping

Hand holds chisel during striking.

PSC recommended control — Fixture/holder or suitable extended striking interface.

46
Jejuri · Open Yard · High

Loading

Workers climb onto trailer/load area to guide loads.

PSC recommended control — Redesign access and remote load-control method; consider platform/alternative loading arrangement.

47
Jejuri · Open Yard · High

Guiding Bin Bucket

Direct touch is used to guide bucket.

PSC recommended control — Remote load control and exclusion position.

90-day direction

Start small. Prove the method. Scale what works.

0–30 days

Select 5–8 repetitive pilot applications across the major exposure families. Capture baseline photographs and complete the hand-function analysis.

30–60 days

Run controlled trials with operators. Modify tools, fixtures, access or process arrangements. Approve only methods that work in real production.

60–90 days

Update SOP/JSA, train relevant teams, establish point-of-use storage and repeat the same photographs to verify that hand-to-hazard separation changed.

Measure the outcome, not the purchase: success is not the number of tools distributed. It is a visible and sustained change in how the task is performed.
Conclusion

The opportunity is larger than a tool programme.

The principal opportunity identified during this assessment is not simply the introduction of more tools. It is the systematic removal of the human hand from functions that do not require the hand itself.

Across Nagar, Baramati and Jejuri, the photographs show both direct hand intervention and an existing instinct to create separation using locally improvised devices. The next step is to turn that instinct into engineering: understand the function, remove the need where practicable, validate the control with operators, standardise the method and verify that it remains in use.

FIND THE HAND™ → UNDERSTAND THE FUNCTION → IDENTIFY THE ENERGY → ENGINEER THE SEPARATION → VALIDATE THE METHOD → STANDARDISE THE CONTROL