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
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)
(TANDATANGAN PENULIS)
Alamat Tetap:
Lot 4518, Rumah M.A.I.T, Kg. Rusila, 21080 Marang, Terengganu Darul Iman.
Tarikh: 28 March 2008
Disahkan oleh:
(TANDATANGAN PENYELIA)
Cop Rasmi:
Tarikh: _______________________
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.
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)
………
ABSTRACT
ABSTRAK
DEDICATION
In God I Trust.
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.
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………...1
1.1 Introduction………..……….1
1.2 Problem Statement……….………..2
1.3 Objectives……….………...3
1.4 Scope………..…...………..4
2. Literature Review………...…5
2.1 Introduction………...…...5
2.2 Definiton of Terms………...…...5
2.3 Safety and Health……….………....7
2.3.1 Health Hazard………...8
2.3.2 Safety Hazard……….……9
2.4 History of Occupational Safety and Health Act (OSHA)………9
2.4.1 Factories & Machinery Act 1967……….………10
2.4.2 Occupational Safety and Health Act (OSHA) 1994…….………...11
2.5 Environmental Issues………..………14
2.5.1.1 Thermal Comfort Hazards...……….…18
2.4.3 Noise Level………..……….18
2.4.3.1 Noise Hazards………..……….………24
2.6 Equipment……….…..…….………..25
2.5.1 QUESTempo 36 – Thermal Environment Monitor…………..…….…….26
2.5.2 Extech Digital Sound Level Meter Model 407730……….………….…..30
3. RESEARCH METHODOLOGY..………..32
3.1 Introduction..……….…..…….………..32
3.2 Research Methodology……….………….32
3.3 Methodology of Study……….….……….34
3.4 Data Collection……….…….35
3.4.1 Questionnaire...………..………..…….….35
3.4.2 Interview..………...….……..35
3.4.3 Observation……….……….…..36
3.4.4 Picture and Video Recording……….36
3.4.5 Measuring Device………..36
3.5 Data Analysis……….36
4. RESULTS AND DISCUSSION…….………..37
4.1 Introduction..……….…..…….………..37
4.2 Results and Data Analysis……….…….…..…….….…….……….….37
4.2.1 Questionnaire Analysis .………..…….….38
4.2.1.1 Gender………38
4.2.1.2 Age……….39
4.2.1.3 Worker Services……….40
4.2.1.4 Working Comfortability……….41
4.2.1.5 Noise Anaysis………41
4.2.1.6 Thermal Comfort Analysis………42
4.2.2 Noise Monitoring Analysis.……….…..43
4.2.2.2 Area 2……….46
4.2.2.3 Area 3……….47
4.2.2.4 Area 4……….49
4.2.3 Thermal Comfort Monitoring Analysis..……….…..50
4.2.3.1 Environment Thermal Comfort ……….51
4.3 Discussion……….……….…….…..…….….…….……….….54
4.3.1 Questionnaire .…………...………..…….….54
4.3.2 Noise Monitoring………...………56
4.3.2.1 Time Weighted Average Noise………58
4.3.3 Thermal Comfort Monitoring………60
5. Conclusion and Recommendation….………..64
5.1 Introduction..……….…..…….………..64
5.2 Conclusion……….…….…..…….….…….……….….64
5.3 Recommendation………...65
5.3.1 Recommendation for Noise………..…….…..65
5.3.1.1 Engineering and Administrative Control…...………65
5.3.1.2 Hearing Protection……….67
5.3.1.3 Warning Sign……….68
5.3.1.4 Information and Training……….……..69
5.3.1 Recommendation for Thermal Comfort…..………..…….…..70
5.3.3 Future Study……….71
REFERENCES………..73
APPENDIXES
LIST OF FIGURES
2.1 Exposure Times versus Noise Level 22
2.2 QUESTemp° 36 26
2.4 Digital Sound Level Meter Model 407730 36
2.5 Weighted Sound Levels 31
3.1 Flow Chart of Research Study 34
4.1 Gender Analysis 38
4.2 Age Analysis 39
4.3 Worker Services 40
4.4 Working Comfortability 41
4.5 Noise Analysis 42
4.6 Thermal Comfort Analysis 43 4.7 Noise Mapping for Noise Level Assessment 44
4.8 Area 1 Noise Level 45
4.9 Area 2 Noise Level 47
4.10 Area 3 Noise Level 48
4.11 Area 4 Noise Level 50
4.12 Location of Thermal Comfort Device Placement 51 4.13 Thermal Comfort Morning Data 52 4.14 Thermal Comfort Afternoon Data 53 4.15 Thermal Comfort Evening Data 54 4.16 Environmental Comparison Analysis 54 4.17 Overall Noise Data for Each Section 56 4.18 Double Spindle Moulder Machine 57 4.19 Example of Non-Hearing Protection Usage 57 4.18 Relationship between PMV and PPD 63
5.1 Example of Silencer 66
5.2 Example of Hearing Protection 68
LIST OF TABLES
2.1 FMA 1967 Regulations 11
2.2 OSHA 1994 Regulation 13
2.4 Determination of Metabolic Rates for Different Activities 16 2.5 Clothing Insulation Values 17 2.6 Typical Minimum Machining Noise Level 19 2.7 Typical Sound Pressure Level 20 2.8 Exposure Times Versus Noise Level 23 2.9 QUESTemp° 36 Specification Table 26
2.10 Heat Exposure Table 28
2.11 Physiological Heat Exposure Limit (PHEL) Time Table 29 2.12 Model 407026 General Specification 30
4.1 Gender Analysis 38
4.2 Age Analysis 39
4.3 Worker Services 40
4.4 Working Comfortability 41
4.5 Noise Analysis 41
4.6 Thermal Comfort Analysis 42 4.7 Overall Noise Data from Area 1 44 4.8 Overall Noise Data from Area 2 46 4.9 Overall Noise Data from Area 3 47 4.10 Overall Noise Data from Area 4 49 4.11 Thermal Comfort Morning Data 51 4.12 Thermal Comfort Afternoon Data 52 4.13 Thermal Comfort Evening Data 53 4.14 Environmental Comparison Analysis 54 4.15 Overall Noise Data for Each Section 56
4.16 PMV Index 60
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
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
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.
always been protected. As for Malaysia Government, OSHA law has been applied to industry ever since year 1994.
1.2 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
(a) To identify risk that could occur in furniture industry in selected areas by using Thermal Environment Monitor QUESTemp o36 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
(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 407730 and QUESTempo36 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
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).
(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).
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) 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.
(b) 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.
(c) 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.
(d) 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.
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) The chemical substance causing the disease may be odorless or invisible. (b) The symptoms may be mistaken for common non-occupational illness.
(c) Disease may not become apparent until many years after the exposure to a hazardous substance.
(d) 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
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 1994.
2.4.1 Factories & Machinery Act 1967
