UNIVERSITI TEKNIKAL MALAYSIA MELAKA OCCUPATIONAL SAFETY HEALTH: IDENTIFICATION OF POTENTIAL RISKS IN FURNITURE INDUSTRY

Transcription

1 UNIVERSITI TEKNIKAL MALAYSIA MELAKA OCCUPATIONAL SAFETY HEALTH: IDENTIFICATION OF POTENTIAL RISKS IN FURNITURE INDUSTRY Thesis submitted in accordance with the requirements of Universiti Teknikal Malaysia Melaka for the Bachelor Degree of Manufacturing Engineering in Manufacturing Management By MD ASYRAF BIN MD ANUAR Faculty of Manufacturing Engineering March 2008

2 UTeM Library (Pind.1/2007) UNIVERSITI TEKNIKAL MALAYSIA MELAKA BORANG PENGESAHAN STATUS TESIS* JUDUL: OCCUPATIONAL SAFETY AND HEALTH: IDENTIFICATION OF POTENTIAL RISKS IN FURNITURE INDUSTRY SESI PENGAJIAN : 2007 / 2008 Saya MD ASYRAF BIN MD ANUAR mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja. 3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD TIDAK TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh: (TANDATANGAN PENULIS) Alamat Tetap: Lot 4518, Rumah M.A.I.T, Kg. Rusila, Marang, Terengganu Darul Iman. Tarikh: 28 March 2008 Cop Rasmi: (TANDATANGAN PENYELIA) Tarikh: * Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.

3 DECLARATION I hereby, declared this thesis entitled Occupational Safety Health: Identification of Potential Risks in Furniture Industry is the results of my own research except as cited in references. Signature :. Author s Name : Md Asyraf Bin Md Anuar Date : 28 March 2008

4 APPROVAL This PSM submitted to the senate of UTeM and has been as partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Management). The members of the supervisory committee are as follow: (En. Amri Bin Sulaiman) (Official Stamp & Date)

5 ABSTRACT This report is about to improve and enhance health rate among workers in industrial by referring the guideline provided by Occupational Safety and Health Act (OSHA) and Factories and Machinery Act (FMA). Therefore, furniture industry has been chosen as a research study because the workers were more easily exposed with potential factors of occupational diseases such as noise pollution and excessive heat temperature at the workplace. In order to identify the rate of noise pollution and excessive heat temperature at the workplace, two measuring devices were used for collecting and recording the data. The collective data were analyzed to determine whether according to the standard provided by Occupational Safety and Health Act (OSHA) and Factories and Machinery Act (FMA). From the research results obtained, the best solution can be practice in industry in order to minimize the accidents and health rate among workers.

6 ABSTRAK Laporan ini disediakan untuk menaik taraf kadar kesihatan dikalangan pekerja di industri dengan berpandukan garis panduan yang disediakan oleh Akta Keselamatan dan Kesihatan Pekerjaan (OSHA) dan Akta Kilang dan Jentera (FMA). Berikutan itu, kilang perabot telah dipilih sebagai tempat kajian kerana pekerja lebih mudah terdedah dengan berbagai-bagai punca ancaman penyakit seperti pencemaran bunyi dan peningkatan haba melampau ditempat kerja. Bagi mengenalpasti kadar pencemaran bunyi dan peningkatan haba melampau ditempat kerja, dua jenis alat pengukuran digunakan bagi membantu mengumpul dan merekod data. Data yang terkumpul akan dianalisa bagi mengenalpasti samada mengikut standard yang ditetapkan oleh Akta Keselamatan dan Kesihatan Pekerjaan (OSHA) dan Akta Kilang dan Jentera (FMA). Hasil analisa kajian diperoleh, penyelesaian terbaik dapat diutarakan bagi meminimakan kadar kemalangan dan masalah kesihatan di kalangan pekerja.

7 DEDICATION In God I Trust. I dedicated to all my beloved family especially to my father, mother, brothers and sisters.

8 ACKNOWLEDGEMENTS Bismillahirrahmanirrahim Praise to Allah Almighty for giving me a chance to complete my PSM. First at all, I would like to thank my beloved parents, Mr. Md Anuar Bin Md Daud and Madam Rafidah Hanom Bte Mohammad for their full support and always be there for me in giving ideas. I would also like to thank all UTeM lecturers and staffs especially to my PSM Supervisor, En Amri Bin Sulaiman for helping me a lot and guiding me to complete this PSM study. In addition, I would like to state my special thanks to all Adunan Komersial Sdn. Bhd. staff, especially to the Operation Manager, Mr. Yazid Bin Hassan who supervise me for my research and others whom their name not been stated. I would like to give a lot of thanks for their support, and assist in terms of their knowledge and information that help me a lot during my research in all Adunan Komersial Sdn. Bhd. Last but not least, my thanks to all of my colleagues that always giving assist for me to finish this research. Without them, I would not be where I m today and completing my study. Thank you again. Wassalam

9 TABLE OF CONTENTS Declaration ii Approval......iii Abstract.... iv Abstrak.....v Dedication....vi Aknowlegment vii Table of Contents viii List of Figures...xi List of Tables xii List of Abbreviations, Symbols, Specialized Nomenclature..xiv 1. INTRODUCTION Introduction Problem Statement Objectives Scope Literature Review Introduction Definiton of Terms Safety and Health Health Hazard Safety Hazard History of Occupational Safety and Health Act (OSHA) Factories & Machinery Act Occupational Safety and Health Act (OSHA) Environmental Issues Thermal Comfort

10 Thermal Comfort Hazards Noise Level Noise Hazards Equipment QUESTemp o 36 Thermal Environment Monitor Extech Digital Sound Level Meter Model RESEARCH METHODOLOGY Introduction Research Methodology Methodology of Study Data Collection Questionnaire Interview Observation Picture and Video Recording Measuring Device Data Analysis RESULTS AND DISCUSSION Introduction Results and Data Analysis Questionnaire Analysis Gender Age Worker Services Working Comfortability Noise Anaysis Thermal Comfort Analysis Noise Monitoring Analysis Area 1. 44

11 Area Area Area Thermal Comfort Monitoring Analysis Environment Thermal Comfort Discussion Questionnaire Noise Monitoring Time Weighted Average Noise Thermal Comfort Monitoring Conclusion and Recommendation Introduction Conclusion Recommendation Recommendation for Noise Engineering and Administrative Control Hearing Protection Warning Sign Information and Training Recommendation for Thermal Comfort Future Study.71 REFERENCES..73 APPENDIXES A B C A set of Questionnaire Noise Level Table Thermal Comfort Table

12 LIST OF FIGURES 2.1 Exposure Times versus Noise Level QUESTemp Digital Sound Level Meter Model Weighted Sound Levels Flow Chart of Research Study Gender Analysis Age Analysis Worker Services Working Comfortability Noise Analysis Thermal Comfort Analysis Noise Mapping for Noise Level Assessment Area 1 Noise Level Area 2 Noise Level Area 3 Noise Level Area 4 Noise Level Location of Thermal Comfort Device Placement Thermal Comfort Morning Data Thermal Comfort Afternoon Data Thermal Comfort Evening Data Environmental Comparison Analysis Overall Noise Data for Each Section Double Spindle Moulder Machine Example of Non-Hearing Protection Usage Relationship between PMV and PPD Example of Silencer Example of Hearing Protection 68 LIST OF TABLES 2.1 FMA 1967 Regulations OSHA 1994 Regulation OSHA 1994 Guidelines and Codes of Practices 13

13 2.4 Determination of Metabolic Rates for Different Activities Clothing Insulation Values Typical Minimum Machining Noise Level Typical Sound Pressure Level Exposure Times Versus Noise Level QUESTemp 36 Specification Table Heat Exposure Table Physiological Heat Exposure Limit (PHEL) Time Table Model General Specification Gender Analysis Age Analysis Worker Services Working Comfortability Noise Analysis Thermal Comfort Analysis Overall Noise Data from Area Overall Noise Data from Area Overall Noise Data from Area Overall Noise Data from Area Thermal Comfort Morning Data Thermal Comfort Afternoon Data Thermal Comfort Evening Data Environmental Comparison Analysis Overall Noise Data for Each Section PMV Index Overall Data for PMV and PPD of Thermal Comfort Example of Warning Signs 68

14 LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED NOMENCLATURE ANSI - American National Standards Institute ASHRAE - American Society of Heating, Refrigerating and Air- Conditioning Engineer db - Decibels DB - Dry Bulb Temperature DOSH - Department of Occupational Safety and Health FMA - Factories and Machinery Act G - Global Temperature HVAC - Heating, Ventilation and Air-Conditioning ILO - International Labor Organization

15 OSHA - Occupational Safety and Health Act PEL - Permissible Exposure Level PMV - Predicted Mean Vote PPD - Predicted Percent Dissatisfied RH - Relative Humidity WB - Wet Bulb Temperature CHAPTER 1 INTRODUCTION 1.1 Introduction Industry is defined as an economic activity concerned with the processing of raw materials and manufacture of goods in factory [Oxford English Dictionary, 2006]. In the early 19 th century, Industrial Revolution occurrence has turned human from agricultural activity to industrial activity where technology or

16 resources were involved; enterprise was required as a capital. The formation of the capital depended on rates of profit and interest. Ever since the, industry has become one of the importance factors influencing the economical financial for each nations. Industries have been categorized into four sectors which are primary, secondary, tertiary, and quaternary sector of industry. The example of the primary sector of industry is agriculture, mining, and raw material extraction. Secondary sector involve manufacturing, tertiary sector is service production, and as for quaternary sector is consisting of intellectual services. Due to industrial progression towards financial increases, it gives opportunity to industry to optimize quantity their finish product where they can fulfill the customers orders and satisfaction. In top of that, the top management urged among the employee to work harder without considering safety and health of their employee. It was shown that, industrial accidents were the commonplace in the country. Many workers have lost their body ability, infected to several diseases, and died during their working hours. This is because there was less protection towards worker safety environment, no legislation and precedent at that time until the public opinion has forced the government to take action to create a law to protect safety health among worker. The milestone in safety movements were beginning rapidly start since year 1867 until the Occupational Health and Safety Act (OSHA) 1974 was introduced in order to guide employer to provide a safety and healthy working environment. The safety movements were corresponded to three major tragedies which were Hawk Nest Tragedy, Asbestos Menace, and Bhopal Tragedy. In today s world, OSHA becomes an important law that should be applied in organizations. The law is always be updated from time to time in order to improve worker safety health and to solve new potential risk so that workers are

17 always been protected. As for Malaysia Government, OSHA law has been applied to industry ever since year Problem Statement In today s industry, there still a high rate of accidents and sickness among workers. Even though an OSHA law has been applied, only small changes occur. The lack awareness among employer and employee of the importance of safety health is one of the reasons. This is because they did not understand the hidden factors affecting human life. Hidden factors are a factor that cannot be seen such as disease affecting from bad environment. It takes certain amount of times before the diseases become worse and incurable diseases. In furniture industry, workers are usually exposed to extreme noise and high environment temperature. An extreme noise can cause loss hearing, less communication, and cause an accident. High temperature will lead to heat stress, heat strain, fatigue, nausea or vomiting, headache, heat cramps, heat exhaustion, heat stroke. Therefore, good environment working area should be provided so it gives comfortable working conditions to worker. An ergonomics factors towards material and machining handling also should be provided where it improve the safety and health. As the results of the research study, company organization able to reduce sickness among workers and increase free-accident zone, able to improve workers safety and health, give awareness to worker and organization about the importance of health and safety, and increase organization productivity and quality. 1.3 Objectives The purposes of this study are:

18 (a) To identify risk that could occur in furniture industry in selected areas by using Thermal Environment Monitor QUESTemp o 36 and Extech Digital Sound Level Meter. (b) To relate the noise and thermal comfort risk with Occupational Safety and Health Act (OSHA) and Factory and Machinery Act (FMA) (c) To make relevant recommendations to eliminate or minimize the potential risks. 1.4 Scope This study discuss about the Occupational Safety Health: Identification of Potential Risk at Furniture Industry. The focuses of the study are on several selected area of workplace that thinks that potentially hazardous to the workers. Furthermore, the data collection will carried out in one hour of three sessions which are morning session (9.00 am to am), afternoon session (1.30 pm to 2.30 pm), and evening session (4.00 pm to 5.00 pm). The main focuses of the potential risks of this research are noise level and the environment heat level of the working area. By focusing on these factors, the potential factors that influence safety and health among workers in furniture industry can be identified. There are two potential factors that will research and discuss which are:

19 (a) Environment Factors i. Noise pollution Environment noise level. ii. Thermal comfort Environment heat level. (b) Safety Factors i. Personal Protective Equipment Hearing Protection. As for noise level monitoring and thermal comfort level monitoring, only Extech Digital Sound Level Meter Model and QUESTemp o 36 Thermal Environment Monitor will be used for data collection and data. The results obtain may be applicable to other company especially for furniture industry CHAPTER 2 LITERATURE REVIEW 2.1 Introduction

20 In this chapter, literature reviews regarding all aspects within the project scope will be highlighted. The three main fields that covered in this chapter are Occupational Safety and Health Act (OSHA), Factories and Machinery Act (FMA), environmental issues and measuring equipment. There were many journal and book referring to the research scope. From the broad area, the review then highlighted three main environmental issues which are noise level, thermal comfort and indoor air quality. Literature review works as a guideline and better understanding to the field of project. It helps to identify the current problems, information, new techniques, and method of study, solution and recommendation. 2.2 Definition of Terms Occupational Safety and Health: Identification of Potential Risk at Wood Industry (b) Occupational i. Of or caused by one s occupational (Oxford English Dictionary, 2006). (b) Of, relating to, or caused by engagement in a particular occupation: occupational hazard (Reader Digest, 2006). (c) Safety i. The condition of being safe (Oxford English Dictionary, 2006). ii. Free from or protected from danger or physical injury (Reader Digest, 2006). (d) Health i. The state of being free from illness and injury (Oxford English Dictionary, 2006). ii. The state of being well and free from illness (Reader Digest, 2006).

21 (e) Identification i. To establish the identity of, to recognize as being specific person or things (Oxford English Dictionary, 2006). ii. The act of identifying (Reader Digest, 2006). (f) Potential i. Having the capacity to develop into something in the future (Oxford English Dictionary, 2006). ii. Capable of becoming possible (Reader Digest, 2006). (g) Risk i. A situation involving exposure to danger (Oxford English Dictionary, 2006). ii. The possibility of something dangerous or unpleasant happening (Reader Digest, 2006). (h) Furniture i. The movable articles needed in a room or house (Oxford English Dictionary, 2006). ii. The movable articles in a room or an establishment that make it fit for living or working (Reader Digest, 2006). (i) Industry i. Economic activity concerned with the processing of raw materials and manufacture of goods in factory (Oxford English Dictionary, 2006). ii. Any type or all types of manufacture and production (Reader Digest, 2006). 2.3 Safety and Health

22 Safety is defined as the condition of being safe [Oxford English Dictionary, 2006] and health is defined the state of being free from illness and injury [Oxford English Dictionary, 2006]. From the definition stated, it shows the relationships between safety and health whereas by having a good environment or good working area, human were protected, secure, and free from any illness and injuries. In industry especially, workers were more tend to expose towards safety hazards and health hazards. This is because there are many factors such visible factors and invisible factors that can affect workers safety and health. Therefore, it is essential for company organization to take the precautions for safety and health of workers. According to the facts based on International Labor Organization (ILO), safety and heath towards human at work were stated as follows: (a) (b) (c) (d) Each day, an average of 6,000 people die as a result of work related accidents or disease, totaling more than 2.2 million work-related deaths a year. From these accidents, about 350,000 deaths are from workplace accidents and more than 1.7 million are from work-related disease. Each year, workers suffer approximately 270 million occupational accidents which lead to absences from work for 3 days or more and fatal victim to some 160 million incidents of work-related disease. There are about 4% of the world s gross domestic product is lost of injury, death disease through absence from work, sickness treatment, disability and survivor benefits. Hazardous substances kill about 438,000 workers annually, and 10% of all skin cancers are estimated to be attributable to workplace exposure to hazardous substance. The International Labor Organization (ILO) has never accepted that injury and disease were related to job. Over the course of the 20 th century, industrialized countries saw a clear decrease in serious injuries because of the advancement in making the workplace healthier and safer. The challenge is that to extend the benefits of this experience to the whole working world. Experience has shown that a preventative safety culture is beneficial for workers, employers and government

23 alike. Various prevention techniques have proven themselves effective, both in avoiding workplace accidents and illness and improving business performance. Today s high safety standards in some countries are a direct result of long term policies encouraging tripartite social dialogue, collective bargaining between trade unions and employers, and effective health and safety legislation backed by strong labor inspection. 2.1 Health Hazard A health hazard is any chemical or biological substance or physical stressor that causes illness in humans. Chemical health hazards occur in many different forms. They can be liquid such as benzene; solids, such as silica dust; or gases such as hydrogen sulfide. The illness caused by exposure to chemical health hazards range from dizziness, nausea, and skin rashes to lung and liver disease, reproductive problems, and cancer. In addition, heat stress and ergonomic hazards such as repetitive motion and awkward postures that contribute to cumulative trauma disorders are common industrial problems. Normally, it is much easier to determine the cause of an injury on the job than it is an illness due to the following reasons: (a) (b) (c) (d) The chemical substance causing the disease may be odorless or invisible. The symptoms may be mistaken for common non-occupational illness. Disease may not become apparent until many years after the exposure to a hazardous substance. The disease or illness may result from the combination of chemicals, substance, or stressors making the exact cause more difficulty to identify. 2.2 Safety Hazard Occupational Safety and Health Act (OSHA) safety standards are primarily concerned with the elimination of unsafe conditions. Even though it is important that workers follow safety rules, history shows that eliminating unsafe conditions is far more effective way to reduce injuries than merely urging workers not to hurt

24 themselves. In general, safety hazards are much more noticeable in the workplace than health hazards. For example, unguarded drive belts and pulleys are high visible, whereas gasoline vapors or lead fumes are nearly invisible. Employee exposure to safety hazards most often provokes an acute response whereas many health hazards have primarily choric effects. Engineering controls seek to eliminate or isolate the hazard thereby reducing the number of hazards in the workplace. 2.4 History of Occupational Safety and Health Act (OSHA) In the early growth of country development, the Malaysia economic structure was depended heavily on agricultural and mining based activity. The growth of these sectors were introduced various hazards to workers. The Selangor Boiler Enactment in 1892 was the first legislation to address industrial safety issues. In year 1913, the Machinery Ordinance was enacted in order to ensure safety of machinery including boiler and internal combustion engines. The Machinery Ordinance 1913 was updated in 1932 (Machinery Enactment 1932) with additional provisions on registration and inspection of machinery installation. The Machinery Ordinance of 1953 superceded all previous legislation related to industrial safety, and was enforced in all the 11 states of Malaysia under the jurisdiction of Machinery Department, Ministry of Labour. Early OSH legislation, the Federated Malay States Mining Enactment of 1926 and the Rump Labor Code of 1933 included public health provisions. Both these legislation required the provision of accommodation, sanitation, medical care and services, decent working conditions and livable wages for the mine and estate workers. Since then, as today s improvement of legislation, two laws were been used in order to protect and secure human safety and health at work which were Factories and Machinery Act 1967 and Occupational Safety and Health Act Factories & Machinery Act 1967 In 1960s, the government implemented a policy to move towards industrialization. This resulted in an increasing number of workers in the manufacturing sector such as microelectronics, chemical and mineral based industries, and in later year s textile and automobile industries. In order to manage