MEM 603 CASE STUDY MFORCE BIKE HOLDINGS SDN. BHD.
Introduction • A group of 5 students in semester semester 7 of the Bachelor of Mechanical Engineering (Manufacturing) (Manufacturing) from the Occupational Safety and Health (MEM603) class group A participated in an industrial visit to MFORCE BIKE HOLDINGS SDN BHD, which is i s located at Bukit Mertajam, Pulau Pinang. The company specialized in the assembly of SYM motorcycles and scooters in Malaysia. SYM is a motorcycle brand from the Sanyang Sanyang Motor Co. Ltd, a company based in Taiwan.
Introduction • A group of 5 students in semester semester 7 of the Bachelor of Mechanical Engineering (Manufacturing) (Manufacturing) from the Occupational Safety and Health (MEM603) class group A participated in an industrial visit to MFORCE BIKE HOLDINGS SDN BHD, which is i s located at Bukit Mertajam, Pulau Pinang. The company specialized in the assembly of SYM motorcycles and scooters in Malaysia. SYM is a motorcycle brand from the Sanyang Sanyang Motor Co. Ltd, a company based in Taiwan.
OBJECTIVE • To design and develop the complete Occupational safety and health program for an industrial organization. • To apply the theories and knowledge gained from lecture in an industrial environment.
Part A- Identify Identify the facility for occupational safety and health that should exist on the site PESENTER KHAIRUL NIZAR
During our visit at the SYM Factory, we had observed some safety facilities that are provided by the company. For example:
Fire Sprinkler Discharges water when the effects of a fire have been detected •
Smoke Detector Smoke detector is a device that senses smoke, typically as an indicator of fire •
Fire extinguisher and Fire hose Fire and safety equipment •
Smoke ventilation system Remove smoke from a building Welding smoke and exhaust smoke •
•
In order to improve the quality of safety at the factory, there are some facilities that could be provided or improved by the SYM Factory. 1. LIFTING EQUIPMENT - The frames were lifted by had from the trolley to the assembly line. This can increase muscle strain and also risk of falling due to improper handling. Recommendation
The use of hoist can reduce the risk of frames falling to the floor or worker. A hoist is a device used for lifting or lowering a load Train all the users, particularly in the use of sling where necessary Always ensure that the weight and distribution of load is not beyond the capacity of equipment being used.
The law and regulation on lifting equipment • Lifting equipment is sufficiently strong and suitable for the proposed used and marked indicates its safe working load. • Lifting equipment is positioned or installed to minimize the injury risk. • Lifting operation are planned, supervised and carried out in a safe manner by people who are competent • Lifting equipment is thoroughly examined for any defect before it is put into service for the first time.
2. NOISE CONTROL - The tools that the workers use such as the air gun produces a loud noise. - Exposure to high levels of noise can cause permanent hearing loss Recommendation SYM Factory could provide personal protective equipment (PPE) headset as methods to overcome noise control
Preventing falls due to slip & trips • Both slips and trips result from some a kind of unintended or unexpected change in the contact between the feet and the ground or walking surface • Some parts of the floor are oily due to engine oil spill. Recommendation • Housekeeping - Good housekeeping is the first and the most important level of preventing falls due to slips and trips. It includes: ▫ cleaning all spills immediately ▫ mopping or sweeping debris from floors ▫ removing obstacles from walkways and always keeping them free of clutter ▫ keeping working areas and walkways well lit • .Flooring - Changing or modifying walking surfaces is the next level of preventing slip and trips. Recoating or replacing floors and installing mats can further improve safety and reduce risk of falling.
Regarding the maintenance program, SYM Factory had implemented the maintenance and testing of fire safety equipment. The maintenance and safety are as follows.
• All fire doors and escape routes should be regularly checked along with associated lighting and signs • Fire-fighting equipment should be regularly checked • Fire detection and alarm equipment should be regularly checked • All other equipment provided to help means of escape arrangements in the building should be regularly checked • Instructions for relevant employees about testing of equipment should be available to make sure those who test and maintain the equipment are properly trained to do so
For the communication tool, we had observed some communication ways that SYM had implemented. For information distribution: 1. Walkie talkie • A walkie talkie is a hand held, portable, two way or multi-way radio transceiver. • It was used by the supervisors and manager at the company to distribute information change and monitor the operation of the factory.
2. Production status display board - Visual communication - To indicate the workers on the target, ideal and actual production that should be done.
For safety purpose: 1. Fire alarms and detectors Ensure existing means of detection discover a fire quickly enough to raise an alarm in time for all the occupants to escape to a safe place The means for giving warning should be clearly heard and understood throughout the whole premises when initiated from any single point If the fire detection and warning system is electrically powered, ensure it has a back-up power supply Ensure employees know about the fire warning system, and that they know how to operate and respond to it Ensure there are instructions/notices for employees on how to operate the fire warning system.
PART B- OSH MANAGEMENT SYSTEM AT PRESENTER MUHAMMAD FAEEZ
Daily Routine
•Procedure check at the assembly line. • Workers do self-check. •Morning talk about safety.
OSH Documentation Level 1
Policy and Scope
Level 2
Procedures
Level 3 and forms
Work instructions, checklists
Level 4
Records
Flowchart of OSH Management System Policy
Organisi ng
Audit
Planning & Implement ation Measuri ng Perform ance Reviewin g Perform ance
Safety Procedure • Wear appropriate clothes given by the company. • Focus when working at the assembly line. • Supervisors monitoring workers’ health and workplace conditions.
Safety Committee Committee Members: • Management Representatives • Employee Representatives • Co-opted workers & others Frequency of Meetings • Every Monday, every week.
Safety Committee Responsibilities: • Statistics on accident records, ill health, sickness absence • Accident investigations and subsequent action; • Inspections of the workplace by enforcing authorities, management or employee health and safety representatives; • Risk assessments; • Health and safety training; • Emergency procedures; and • Changes in the workplace affecting the health, safety and welfare of employees.
Awareness/Training • • • • •
Fire Drill Training. Emergency training; First Aid . Observing the workplace; Possible harm. Operating Machines and Tools. How-to assemble motorcycle parts accordingly.
Inspection Procedure
Application of PPE • Gloves
• Safety Boot Protections
Safety Helmets
Safety Apron
Safety Goggles
Ear
Notification Warning
Fire Alarm Fire Alarm Switch
Fire Alarm Bell
Fire Strobe Light
Part C-Procedures & activities need to be carried out in the event of an Emergency/injury/accident/ incident PRESENTER MUHAMAD RAZWAN
FIRE
Figure 1 : Escape Plan of
MFORCE SDN. BHD • Escape Routes Employer do fire drill at least once per year to ensures employees know fire escape plan All escape routes are clearly marked and approve by fire brigade
Figure 2 : Fire extinguisher
Fire
Fighting - Small fire - Fire extinguisher at workplace -Inspect regularly to keep in good working condition
Figure 3 : Evacuation plan of MFORCE SDN BHD
Fire
evacuations Assemble at evacuation assembly
point Check employees have escaped safely
FIRE PROCEDURE Sound fire alarm and alert all workers to evacuate Alert fire brigade Leave buiding immediately( escape route) Assemble with other staff at evacuation assembly point Inform firefighters of the situation
When an injury or accident is known to have occurred:
• First person nears victim must confirm exact location of the affected and • • • • • •
the nature of the incident. Report the details to the Supervisor. Send the victim to the designated Assembly Area. Confirm details of incident (name, organisation of person(s), nature of injury/illness). Notify relevant section manager as soon as possible. When a patient is transported to hospital, a person from the same organisation and known to the patient should proceed to the hospital. Reporting and notification – refer to the Reporting injuries and fatalities procedure
• First –aid Minor injuries Preventing further complications from injury
PART D - What type of hazards that may occur and how are they avoided? PRESENTER AMIRUN NISYAM
1. Risk of motorcycle frame to fall down a) The frames were lifted by had from the trolley to the assembly line. This can increase muscle strain and also risk of falling due to improper handling. b) Workers use fabric gloves while working. Fabric gloves are slippery which may lead to loss of grip while lifting the frames.
D. What type of hazards that may occur and how are they avoided? ▫ Suggestion 1 : The use of hoist can reduce the risk of frames falling to the floor or worker.
D. What type of hazards that may occur and how are they avoided? ▫ Suggestion 2: The use of rubber/synthetic surfaced gloves reduces the risk of loss of grip.
D. What type of hazards that may occur and how are they avoided? 2. Noise a) The tools that the workers use such as the air gun produces a loud noise. b) Constant exposure of this noise might contribute to hearing damage.
D. What type of hazards that may occur and how are they avoided? •
Suggestion: The use of PPE headsets can reduce the stress on the hearing of the workers.
D. What type of hazards that may occur and how are they avoided? 3. Too much workforce on a single line ▫ The line is really packed with workers ▫ Collision might occur between the workers ▫ Workers might lose the grip of tools/components they are handling ▫ This can be hazardous and also costly ▫ Suggestion: Increase workspace area by preassembling certain parts outside the main assembly line
D. What type of hazards that may occur and how are they avoided? 3. Too much workforce on a single line ▫ The line is really packed with workers ▫ Collision might occur between the workers ▫ Workers might lose the grip of tools/components they are handling ▫ This can be hazardous and also costly ▫ Suggestion: Increase workspace area by preassembling certain parts outside the main assembly line.
D. What type of hazards that may occur and how are they avoided? 4. Improper handling of assembled bikes ▫ The worker did not ride the bike properly ▫ Improper seat position ▫ Accidents can occur ▫ Slippery floor ▫ Suggestion: ride properly.
E: COST OF PRACTICING OSH IN FACILITIES AND COMPARE WITH DOWNTIME COST PRESENTER MUHAMAD HAZIQ
Facilities Costs Accidential Prevention
Cost and Description Air compressor Motor: 7.5kw / 10hp Working Pressure (kg/cm²): 12 Bar (Max. 16 Bar) Compressor Speed 850 rpm Tank Capacity: 237 Liter Compressor Block Physical Dimension (L x W x H): 700mm x 460mm x 560mm Weight: 262 kg Dimension: 1470mm x 650mm x 1150mm Price: RM 10,600/unit
Accidential Prevention
Cost and Description Metal table Price: RM200/unit
Accidential Prevention
Cost and Description Gas welding (Oxy-Acetylene) Cutting torch dimension: 18” Price: RM 1,325/set
Accidential Prevention
Cost and Description Forklift Truck (Toyota) Load capacity: 2000 – 2500 kg Power: Diesel powered Price: RM28,000/unit
Planning costs Accident Prevention Hired OSH officer
Planning cost RM 42,000.00per year
Safety audit Safe handling of forklift truck
RM 500.00 per person
Welder
RM 1,000.00 per person
PPE training
RM 80.00 per person
Developing effective SHC
RM 2,000.00 per person
HIRARC training
RM 4,000.00
Incident costs Incident Consequence
Estimated cost
Using hand tools
Eye damages, cuts and gashes, strain
RM 500.00
Uncovered machine
Hand get caught into rotating part
RM 10,000.00
Wet and greasy floors
Slip, trips and falls
RM 30,000.00
Constant loud noise
Damage hearing, hearing loss
RM 50,000.00
Frequent lifting
Sore muscle, fatigue, RM 10,000.00 serious long term illness
Blocked fire exits
Difficulties when incident occur
RM 100,000.00
Comparison between preventive and Incident identification Preventive cost incident costsIncident cost Uncovered machine
RM 10 000.00
RM 8000.00
Wet and greasy floors
RM 30 000.00
RM 10 800.00
Sharp chip formation
RM 5000.00
RM 8000.00
Constant loud noise
RM 50 000.00
RM 8000.00
Blocked fire exits
RM 100 000.00
RM 10 000.00
Frequent lifting Using hand tools
RM 20 000.00
RM 15 000.00
RM 500.00
RM 400.00
Stairs-Frayed Carpet Slips and trips
RM 2000.00
RM 9000.00
RM 1000.00
RM 500.00
At
doorways
(rain),
spillages Improperly cleaning chip RM 500.00
RM 200.00
