Auto sector worker’s Factory Maps of hotspots of injuries

Safe in India
2 days ago
4 min read

Updated: 1 day ago

Factory Maps are tools to identify unsafe hotspots in factories – Workers share their 'Participatory Research'

Introduction :

Safe in India Foundation (SII), in collaboration with Praxis Institute for Participatory Practices and eight Shramik Saathis, conducted year-long participatory research. The Shramik Saathis' were trained to engage with fellow workers, collect insights, and document workplace safety issues. One of the key tools used was participatory factory mapping—an exercise that enabled workers to visually represent hazardous zones within their factories and identify the nature of risks they regularly face.

Through this visual process, workers were encouraged to rethink familiar routines and highlight risks that had become normalized or overlooked over time.

These maps helped workers reflect on their daily routines and recognize both immediate and long-term safety threats they may have become desensitized to. Identified risks ranged from environmental issues such as heat, poor ventilation, and inadequate lighting to specific operational dangers involving lifting machinery, power presses, narrow spaces between machines, limited emergency exits, and unhygienic conditions like inadequate toilets and clean water.

Workers drew either detailed layouts of their own factory floors or generic versions that captured the essential structure and operations of shopfloors.

The mapped factory floors and layouts, revealed hidden dangers often missed in traditional audits, constrained by compliance checklists and gave deeper insights into real-time safety conditions, machinery placement, restrooms, walkways, and storage strengthening SII’s mission to enhance occupational health and safety standards.

Each group – different factories and different issues -

By engaging groups of workers from varied settings, we were able to capture a broad and nuanced spectrum of safety concerns.

Rough layouts, developed by groups focused on different factories and concerns, identified injury hotspots. The process involved both individual and group efforts, enabling a holistic understanding of the daily operations and existing safety measures.

Key Safety Concerns Identified:

1. On the Shopfloor:

Infrastructure Deficits: Common risks included absent safety gear (helmets, shoes), manual dye handling causing foot injuries, and poor ventilation leading to exhaustion/respiratory issues.
Hazards: Slippery floors, clutter, and loose wiring increased fall/shock risks.
Ergonomic Stress: Poor workstations caused unnatural postures and repetitive strain, leading to back/joint injuries.
Low Visibility: Dim lighting caused eye strain, misjudgements, and accidents (e.g., increased hand injuries during metal cutting).
Environment: Heat, noise, and poor ventilation reduced safety and productivity, causing heat stress and respiratory issues.
Injury History: Unrecorded near-misses and past injuries indicated recurring risks, highlighting the need for proactive mitigation.

2. On Machines:

Neglect & Pressure: Machinery risks were high due to ignored wear, breakages (e.g., power press double-strokes), and irregular maintenance.
Safety Lapses: Production pressure and absent guards led to crushed hands. Workers disabling safety mechanisms under pressure escalated risks.

3. Packing:

Mixed Hazards: Ergonomic and operational risks were prevalent.
Deficiencies: No safety shoes/gloves caused cuts. Lack of seating led to strain/back issues. Absent dustbins and trolleys resulted in clutter, tripping hazards, and manual handling risks.

4. Godown:

Heavy Lifting Risks: Major contributors to physical strain.
Lack of Aids: No lifting equipment or mechanical aids for loading/unloading caused injuries from falling materials and severe spinal/back issues.
Loading/Unloading Hazards: Unsafe paths (e.g., speeding forklifts at docks) and blind spots increased risks.

5. Toolroom:

Design Flaws: Small oversights and absent safety equipment led to high risks.
Hazards: No tool-lifting equipment increased manual handling injuries. Absent safety shoes caused foot injuries from falling tools. Narrow, unstable racks posed serious hazards.

6. Lack of Facilities:

Worker Dignity: Chronic neglect of basic facilities reflected deeper health and dignity concerns.
Water & Toilets: Unclean drinking water led to dehydration and kidney issues. Poor hygiene and inaccessibility of toilets (e.g., for female workers avoiding visits) resulted in infections and dehydration.

What Do the Maps Reveal?

An overall lack of respect for the basic needs of workers and the desire to provide a professional and safe work environment is evident.

Notices are displayed in English

Factory layouts are changed gradually moving away from the one submitted to get the government clearances to add more equipment in the same space taking over walkways and making emergency exits difficult to access.

Do These Maps Help Where standard checklists Lag?

Beyond Compliance Checklists: Safety railings may exist but could be too low to be effective—only workers can provide such contextual feedback.

Firsthand Risk Identification: Near-miss accidents often go unreported but are captured through mapping, revealing real safety levels.

Chronic Health Risks: Long-term exposure, such as poor ventilation in painting sections, presents risks not flagged by routine checks.

Mental and Emotional Strain: Mapping reveals psychological stress zones caused by hostile supervision and unrealistic targets.

Marginalized Worker Challenges: Women and migrants face harassment and inaccessible facilities, such as distant or shared restrooms.

How can this be used to improve factory?

Participatory Body maps translate risk into actionable data, aiding factory safety planning and compliance.

Compliance with Indian Safety Regulations:
- Helps factories adhere to labour and worker safety regulations.
- Assists government (e.g., Directorate IS&H) with an audit/inspection checklist.
- Supports factory upgrades for ISO/BIS safety standards, improving certification.

Preventing Common Workplace Hazards:
- Electrical Safety: Maps highlight overloaded circuits/exposed wiring for maintenance.
- Immediate Action: Marks high-risk zones (wet floors, clutter) to prevent slips/trips.
Ensuring Better Working Conditions:
- Space: Maps/pictorial evidence push for better factory spacing to reduce accidents from cramped areas.
- Fatigue: Addresses fatigue risks and related accidents, including long hours.
- Facilities: Improves sanitation, drinking water, and ventilation, reducing health risks.

Enhancing Worker Participation & Awareness:
- Capacity Building: Trains workers on machine functioning and daily operations via safety programs specific to factory conditions.
- Awareness Materials: Develops multilingual safety communication using maps for better understanding.
Reducing Downtime & Increasing Productivity:
- Synchronization: Fosters greater coordination between Production and HR.
- Proactive Safety: Minimizes disruptions for smooth, accident-free operations by addressing worker concerns.
- Cost Reduction: Leads to reduced compensation and medical costs.
Ultimately, these maps offer far more than visual data—they represent a participatory process that centres worker agency in shaping safer workplaces.
By empowering workers to visually articulate the risks they face daily, these maps unveil hidden dangers and nuanced issues often missed by traditional methods. This worker-driven insight is crucial for the Safe in India Foundation's mission, paving the way for more targeted interventions, improved working conditions, and ultimately, the prevention of workplace injuries and illnesses. Embracing participatory mapping is not just about compliance; it is about fostering a culture of safety where workers are active participants in creating healthier and more secure work environments.