Environment, Health and Safety Manager

Role Purpose :

To ensure safe operations in Body Assembly, Robotic Welding Cells, Manual Welding Stations, Material Handling & Fixture Change Areas, and drive a proactive safety culture. The role focuses on machine safeguarding, electrical & energy isolation, welding hazard control, chemical/fume safety, and compliance with legal & customer EHS requirements.

Education - Diploma / BE in Mechanical / Production / Industrial Engineering

Safety Qualification - Mandatory: ADIS / Diploma in Industrial Safety ( MSBTE )

Experience - 5–12 years in Assembly / Welding shop safety (Automotive / Fabrication industry)

Standards Knowledge - Robotic programming basics, welding process knowledge, LOTO, PPE, ventilation systems

Skills -Risk assessment, incident investigation, safety audit, shop floor training and communication

Computer Skills: MS Office, Excel Reporting, Incident Reporting Tools.

Key Responsibilities :

• Monitor daily shop floor safety in robotic welding lines, MIG/TIG manual welding bays, spot welding machines, projection welding, and assembly stations.
• Ensure safety of robotic systems, including:

Safety interlocks

Light curtains / area scanners

Emergency stop & safety PLC functionality

Robotic teach mode protection

Restricted robotic working zones

• Enforce use of welding PPE: auto-darkening helmets, gloves, aprons, safety shoes, sleeves.
• Establish safe practices for fixture change, gun change, torch replacement & electrode dressing.
• Ensure welding fume capture, exhaust ventilation (LEV), and air quality monitoring.
• Conduct HIRA / JSA for robotic and manual welding operations.
• Lead incident, near-miss & unsafe act investigations and ensure CAPA implementation.
• Implement LOTO / Permit to Work system for robot maintenance, welding machine repair, utility lines, and electrical panels.
• Develop and implement Standard Operating Procedures (SOPs) for:

Robot teaching & reprogramming

Fixture maintenance

Gas cylinder handling

Welding booth housekeeping and ventilation

Conduct structured training for :

Safe welding practices & ergonomics

Arc flash & electric shock prevention

Robotic cell entry & emergency response

LOTO & confined space safety

• Develop Safety Champions among supervisors and team leaders.
• Ensure compliance with Factories Act / OSH Code, ISO 45001, customer EHS audits, and internal audit requirements.
• Maintain documentation on:

Welding fume exposure monitoring

Robotic & electrical maintenance safety checks

PPE & training records

Fire safety & emergency preparedness

• Conduct Toolbox Talks and Behavior-Based Safety (BBS) drives.
• Conduct mock drills and maintain first aid & emergency response capability in shop.
• Lead fire & explosion prevention measures, especially in gas storage & welding zones.
• Ensure safe storage and handling of CO₂, Argon, LPG, Acetylene, and shield gases.
• Ensure proper flashback arrestors, leak checks, manifold system inspections.
• Verify MSDS availability for welding consumables, anti-spatter spray, coolants, greases.