hse assignment 3 final

7/25/2019 HSE Assignment 3 Final

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HEALTH SAFETY AND

ENVIRONMENT

Assignment 3

CASE STUDY OF AUTOMOBILE WORKSHOP

GROUP MEMBERS : LUQMAN HAKIM BIN ROSLI 16098

CHAN SIN WEI 16173

POR HONG YANG 16148

ABDULQODOS MOHAMMED AL-ORABI 1780

ARE!OO SHAHRA!AD 1774

LEC"URER#S NAME : DR ABRAR INAYA"

Table of Content


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1. Summary

2. Introduction of Case Study

3. Developing risk scenario4. ustification of t!e met!od used

". #rocedure of met!od

$. %ault Tree Dra&ing'. Identifying and assessing all possible risks &it! !a(ards

). Conse*uences if an accident occurs

+. ,et!od of controlling t!e risk1-. Solution to minimi(e risk

11. Conclusion

12. eference

Summary


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In t!is case study/ &e &ill be talking about t!e various !a(ards and t!e risk associated &it! t!em

in our industry of interest/ automotive &orks!op. 0e &ill be focusing mainly on t!e &orks!ops

activities suc! as t!e type of &ork for everyday operation and t!e !a(ards t!at come &it! t!at

&orking operation. 0e &ill be discussing &!at kind of !a(ards a &orker is eposed to and t!e

risks !e may face. %or t!is matter/ &e &ill use %ault Tree nalysis to create a risk scenario to

better understand t!e !a(ards and risks. In addition/ &e &ill also be discussing t!e advantages

and disadvantages of using %T and look at t!e procedure of %T to fully understand it. %inally/

after all t!e !a(ards and risks !ave been identified/ &e &ill proceed to discuss t!e met!ods and

solutions to rectify t!e problems.


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Introduction to Case Study

0e !ave decided to make automotive factory as our case study for our ealt! Safety

5nvironment 6S57 assignment.

In ,alaysia/ automotive manufacturing !as contributed to t!e nations annual income. T!is

industry !as !elped t!e country make a !uge fortune by selling t!e automobiles locally or

eporting to ot!er countries. %urt!ermore/ t!e country !as also successfully attracted prestigious

automotive brands from overseas suc! as 8,0/ ,ercedes98en( and onda to build t!eir

assemble plants in t!e country. T!ere are currently 2) automotive companies from overseas to

date. T!is in turn !as created a :ob opportunity for ,alaysians as &ell as foreign &orker to

involve t!emselves in t!is industry so as to cater t!e needs of t!e rapid9gro&ing industry.

;nfortunately/ every year too many people are in:ured &!ile &orking in automotive &orks!ops.

In:uries are considered as a menace to t!e industry as &ell as for t!e &orkers. 0orkers are

constantly eposed to uncertain !a(ards t!at could be life9t!reatening. ccording to


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of t!e systems of &ork used by employees and t!e proper training and supervision of employees

to keep t!em safe at &ork. egulations made under t!e ct provide additional instruction on !o&

particular !a(ards/ suc! as asbestos/ !a(ardous substances/ manual !andling and plant/ are to be

managed. 5mployees also !ave t!eir o&n duty to take reasonable care for t!eir o&n !ealt! and

safety at &ork and to avoid endangering t!e !ealt! and safety of any ot!er person by anyt!ing

t!ey do/ or fail to do/ at t!e &orkplace.

s &e kno&/ accidents are avoidable at some costs if necessary safety measures are considered at

t!e &orkplace. It is !ig! time t!at risks at automotive &orks!ops s!ould be minimised to protect

t!e lives of &orkers. ,aking t!e environment safer is important so t!at every &orker &ill feel

comfortable &!ile &orking &it! !a(ardous components and mac!inery. %or t!is assignment/ &e

!ope to develop a risk scenario at t!e automotive factory and find a solution to minimise t!e risk.


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Developing risk scenario

Various Hazards in Automotive Workshop

s mentioned earlier in t!e introduction/ our pro:ect is focused on t!e events and activities t!at

!appens in automotive &orks!op. T!e construction and repair process of automobiles gives a lotof benefits to mankind but one must not forget t!e !a(ard t!at comes &it! t!e :ob. 0!ile t!e :ob

scope seemed &it! increasing &ork related eperience/ t!e !a(ard faced everyday by t!e &orkers

pose a great deal of problem to t!e &orker and surrounding.

mong t!e !a(ards t!at are present in automotive &orks!op are listed belo& in t!eir respective

areas

Working with automotive vehicles in the workshop

17 8usy traffic and no eclusion (ones or barriers for specified areas or &orkplaces for cars

and &orkers.27 ;nsupervised usage of ve!icles &it!out clearance &it!in t!e &orks!op37 ;nmonitored civilian movement &it!in dangerous area suc! as near po&er tools and too

close to ve!icle repairing area

47 Be!icle in repair not tied do&n properly

"7 ;nmaintained floors of t!e &orks!op suc! as oil spill and uneven or cracked floor

$7 ;nsafe &ork conditions suc! as &orking near !ig!ly flammable or !armful c!emical

materials

'7 ;sage of po&er tools and e*uipment &it!out certificate of competency

Usage o liting e!uipment

17 ;sage of damaged or uninspected ve!icle !oists

27 ;nmaintained !ydraulic and trolley :acks. o ve!icle stands used &!en ve!icle is raised

by !ydraulic :ack

37 ;nsecured ve!icle ramps &!ic! may cause ve!icle movement

Storage and "acking o #arts

17 ;nbalanced and tyres stacked too !ig! &!ic! !as a !ig! c!ances of tyres falling27 Tyre or parts storage racking above s!oulder !eig!t

37 ;nsecured ladders to pick up parts

47 Tyres or !eavy e*uipment lifted or moved by !and instead of assisting e*uipment


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Handling o heavy parts

17 5ngines t!at needs to be replaced are removed &it!out calculations on t!e strengt! of

supporting e*uipment

27 #arts are removed &it!out !andling aids

"isk Scenario

ll t!e !a(ards t!at are commonly meet during t!e &orking period inside t!e &orks!op !ave

been listed before!and. To better understand all t!e !a(ard listed/ it is best &e see !o& t!ey relate

to eac! ot!er. 8elo& is a risk scenario developed by using fault tree analysis.

Top event Serious #ersonnel In:ury> in all &orking eperience/ &e take precaution to avoid

getting in:ured at &ork.

%irst case serious personnel in:ury can come in many factor/ one of t!em is &it! an accident

&it! a repair ve!icle. ormally/ a repair ve!icle re*uires t!at it be !oisted up in order to accesst!e lo&er part of t!e ve!icle but sometimes t!e ve!icle can move or slip t!us resulting in an

accident bet&een t!e ve!icle and t!e &orker. T!e slipping can come from 2 factor/ eit!er t!e

!andbrake of t!e ve!icle &as turned off or t!e c!ocks for t!e &!eels are damages. ccident &it!

t!e repair ve!icle can also come from eternal factor suc! as an unsupervised driving from

civilian into t!e &ork area &!ic! is caused by confusion of t!e customer. 0!en t!ere is no

specific &aiting area for t!e customer to drop off !is or !er ve!icle/ s!e or !e mig!t drive into

t!e &orks!op &it!out supervision resulting in an accident

Second case serious personnel in:ury can also come from a simple case of tripping &!ile

&orking. T!e main reason from tripping is from an oil spill &!ic! &as left alone &it!out any

cleaning or covering. T!is result in a !ig! c!ance of slipping in &!ic! t!e &orker mig!t slip and

fall

T!ird case t!e least probable event in &!ic! a &orker could get !urt is if s!e or !e carries

!eavy parts of t!e ve!icle &it!out any !andling aid. s t!e parts are sometimes very !eavy/ for

eample t!e engine/ t!e &eig!t mig!t be too muc! too bear and can result in dropping and !itting

a &orker.

$ethod to develop the risk scenario


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s mentioned earlier/ &e !ave developed a risk scenario from all t!e !a(ards t!at !ave been

identified in t!e &orks!op. o&ever/ to develop a good and efficient risk scenario is difficult if

t!e met!ods to create t!em are not used. To develop a risk scenario/ &e can eit!er use %ault Tree

nalysis/ 5vent Tree or EA#. %or our risk analysis/ &e !ave c!osen t!e %ault Tree nalysis.

0!at is a %ault Tree nalysisF

%ault Tree nalysis or %T in its simplicity is a top do&n approac! starting &it! t!e un&anted

conse*uences as t!e top event and identifying all possible factors t!at could contribute to t!e top

event. %T is a failure analysis tec!ni*ue/ it involves eamining preceding events t!at leads up to

t!e top event &!ic! is a normally a system failure. %T are deductive met!od for identifying

&ays in &!ic! !a(ards can lead to an accident.

T!e procedure of developing t!e fault tree is s!o&n belo&.

%ault Tree nalysis

1. Determine t!e most undesirable event &!ic! is considered t!e Top 5vent. T!e Top 5vent

must only be one.2. %rom t!e Top 5vent/ &e must determine t!e events t!at contribute to it. T!e number of

contributing events can be as many as possible.

3. %rom t!e contributing event t!at causes t!e Top 5vent/ &e must identify t!e relations!ip

bet&een t!em in terms of D and A gates.4. If t!ere are any events t!at leads to t!e contributing events/ &!ic! are called 8asic

5vents/ it must also be listed in t!e %ault Tree. T!e 8asic 5vents can be as many as

possible.

". T!e relations!ip bet&een t!e 8asic 5vents and t!e contributing events must also be

identify.

T!ere are many uses for %T/ belo& are some of t!em

;nderstanding t!e logic leading to t!e top event

#rioriti(ing t!e contributing events t!at causes t!e top event To assist in designing a more efficient system

s a diagnostic tool to identify and correct causes of t!e top event

%ustiication o the method


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0!y do &e use %T to create t!e risk analysisF T!e ans&er is simply because t!e advantages of

using it is more t!an t!e disadvantages.

dvantages of %T

It is very simple to understand at first glance and t!e contributing events t!at can be

easily interpreted.

It can be used to s!o& multiple failures or combinations of failures t!at leads to t!e top

event.

T!e pat! t!at leads to t!e top event can easily be seen and rectified.

T!e pat! generated is easily understood by &orkers to avoid doing t!e events.

Disadvantages of %T

To understand t!e events re*uire deep kno&ledge of t!e system and t!e &ork situation

ot practical on systems &it! large numbers of safety critical failures.

T!e pat! can gro& to become very comple.

s listed above/ it can be seen t!at a %T risk analysis is best for a &orks!op environment due to

t!e fact t!at t!ere are not muc! safety critical failures as t!e !a(ards are simple and t!e %T &illnot be comple due to t!e simplicity of t!e &orking environment in t!e &orks!op. T!e pat!

developed is easy enoug! for all t!e &orkers to understand at first glance and it !as covered over

+-? of t!e possible risks and !a(ards. %inally/ t!e &orks!op environment does not rely too

!eavily on mac!inery until it poses a t!reat rat!er !uman error &!ic! is most of t!e times can be

rectify before t!ings get out of !and


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&ault 'ree Drawing

%ustiication o the methodC$%&' (%)

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0!y do &e use %T to create t!e risk analysisF T!e ans&er is simply because t!e advantages of

using it is more t!an t!e disadvantages.

dvantages of %T

It is very simple to understand at first glance and t!e contributing events t!at can be

easily interpreted.

It can be used to s!o& multiple failures or combinations of failures t!at leads to t!e top

event.

T!e pat! t!at leads to t!e top event can easily be seen and rectified.

T!e pat! generated is easily understood by &orkers to avoid doing t!e events.

Disadvantages of %T

To understand t!e events re*uire deep kno&ledge of t!e system and t!e &ork situation

ot practical on systems &it! large numbers of safety critical failures.

T!e pat! can gro& to become very comple.

s listed above/ it can be seen t!at a %T risk analysis is best for a &orks!op environment due to

t!e fact t!at t!ere are not muc! safety critical failures as t!e !a(ards are simple and t!e %T &illnot be comple due to t!e simplicity of t!e &orking environment in t!e &orks!op. T!e pat!

developed is easy enoug! for all t!e &orkers to understand at first glance and it !as covered over

+-? of t!e possible risks and !a(ards. %inally/ t!e &orks!op environment does not rely too

!eavily on mac!inery until it poses a t!reat rat!er !uman error &!ic! is most of t!e times can be

rectify before t!ings get out of !and


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Identiying and assessing all the possi(le risk with hazards

0!at are t!e !a(ardsF 0!o mig!t be !armed

and !o&F

0!at are you already doingF

a(ardous substances

Contact &it! used

engine oil etc during

servicing

Skin contact over a

long period can lead

to severe dermatitis

and skin cancer.

G itrile gloves supplied and used

G @arage overalls supplied and used

G Contract for regular cleaning of overalls

G 0orkers informed to clean !ands t!oroug!ly

and use skin creams provided after contact &it!

!a(ardous substances

Car engine running

inside/ toic e!aust

fumes/ eg carbon

monoide

T!e fumes may cause

eye irritation and

breat!ing difficulties.

G Car e!aust attac!ed to etractor system &!en

engine is running

G 5tractor system maintained and tested to

prevent leaks

%ire

#etrol and


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is overc!arged and

eplodes.

5lectrical e*uipment

#ortable appliances/

eg !and lamps.

0orkers could get

electrical s!ocks or

burns from faulty

electrical e*uipment

or on installation.

5lectrical faults can

also lead to fires.

G


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0ork involving air

conditioning systems

0orkers could suffer>

G frostbite t!roug!

skin or eye contact

&it! refrigerant li*uid

or gas G asp!yiation

if sufficient

*uantities of gas

escape into confined

space

G eposure to !armful

gases t!roug!

t!ermal

decomposition of

refrigerant if eposed

to a naked flame.

G 0orkers are trained in correct procedures

Compressed air

5plosion of

e*uipment tyres

0orkers could suffer

blast in:uries from

tyre or e*uipment

eplosion. 0orkers

could suffer damage

to internal organs if

air is introduced into

t!e body.

G ll &orkers trained in safe &orking procedures

and dangers of !orseplay

G irline !as deadmans !andle

G System inspected and serviced every year by

insurers

andling ve!icle air

bags

ir bags could

eplode &!en not

fitted/ causing in:ury.

G ;nits are stored in suitable cabinet of t!eir

o&n

G 0orkers are trained in correct !andling and

fitting G %aulty units are returned to supplier for

disposal


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,anual !andling

,ovement of

components

0orkers risk in:uries

or back pain or pain

else&!ere from

!andling !eavy andHor

bulky ob:ects.

G 0orkers are trained in safe manual !andling

and to ensure contractors follo& safe manual

!andling tec!ni*ues

G ,anual !andling aids are available/ eg lift

truck

Be!icle movements 0orkers and

customers risk

potentially serious

in:ury if struck by a

moving ve!icle

G Safe parking provided for customers &it!out

need for reversing

G ,arked &alk&ays for pedestrians

G Be!icles driven slo&ly around premises

G 0orkers ensure t!at cars being manually

pus!ed al&ays !ave a person seated at t!e &!eel/

to keep t!e ve!icle under control

Slips and trips Door&ays 6rain7/spillages/ uneven

surfaces

0orkers and

customers may be

in:ured if t!ey trip

over ob:ects or slip on

spillages/ eg oil or

&ater.

G @ood !ousekeeping standards maintainedt!roug! training and monitoring

G %loors degreased &eekly

G bsorbent granules and sa&dust put on spills

as soon as possible

G 5ntrances and eits maintained


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0orking at !eig!t %alls from any !eig!t

can cause bruising

and fractures and

potentially serious

in:uries.

G ppropriate access e*uipment is provided for

&ork on trailers and tops of commercial ve!icles

G andrails fitted at edges of raised storage

areas and access stair&ay provided

G 0orkers are competent to use ladders &!ere

appropriate

G Be!icle inspection pits clearly marked and

covered &!en not in use


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$ethod o controlling the risk

1> Do not rely on safe be!avior as t!e main means of preventing in:ury Safety solutions t!at rely

on administrative controls suc! as training/ supervision/ and procedures/ re*uire constant

vigilance and effort to maintain. #!ysical c!anges suc! as improved &orkplace layout do notre*uire t!e same level of effort and are more effective and a sustainable means of in:ury

prevention.

2> ;se mec!anical devices to reduce !eavy lifting/ a&k&ard postures/ sustained postures and

ot!er body stressing ,any mec!anical devices are already in use/ suc! as tools po&ered by

compressed air/ !oists/ cranes and lifting !ooks/bead breakers/and body under slides to get under

ve!icles. Some devices are &idely kno&n but used less often/ suc! as vacuum lifters for

&indscreen insertion/using !oists &!en detailing/!ip9!eig!t roller conveyor and ramps to load

and move tyres/ order picking ladders &it! load tables for stock access/ pads and body tables for

comfortable &ork in foot&ells and under das!es and castors on !eavy toolboes. fe&&orkplaces apply innovative ideas suc! as tyre under slide and using over!ead9mounted body

support !arnesses for &ork over t!e engine bay. If t!e e*uipment eists to reduce t!e risk of body

stressing t!en it s!ould be purc!ased and used.

3> Searc! &idely for solutions and c!allenge t!ats t!e &ay it !as al&ays been done

8ecause people do not epect to go !ome in:ured or maimed from &ork/ &!at people accept as

t!e normal &ay of doing t!ings !as c!anged. ,anagers/ o&ners and employees need to

recogni(e t!is. %or eample/ for &orking safely &it! ale stands and :acks t!e ustralian

Standards are t!e reasonable best starting point/ !o&ever some automotive &orks!ops do not

apply t!e safety standards in t!ese document.


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Solution to minimize the risk

Documented traffic management plan and signage &!ic! does not permit customers to drive t!eir

ve!icle &it!in a &orks!op/ e.g. customer service area for ve!icle drop9off employee movesve!icle out of &orks!op and into customer car parkHpick up area.

Be!icle traffic is p!ysically segregated from service personnel and pedestrians.

5mployees drive &it!in t!eir license and competency.

0!en &orking on trucks/ trailers/ eart! moving e*uipment or farm ve!icles ve!icle dropped off

and moved to designated repair area by licensed operator &it! appropriate eperience.

Be!icle is prevented from moving by using t!ree of t!ese met!ods

J =eys are removed from t!e ignition

J T!e !and brake is on

J 0!eels are c!ocked on bot! sides of t!e ve!icle using serviceable purpose9built c!ocks

J Be!icle raised on a pillar !oist &it! all &!eels off t!e ground.

ll leads are stored out of t!e &ay/ e.g. retractable reels. #o&er and pneumatic outlets located

close to t!e service area. Spills/ including &ater spills/ are covered &it! absorbent material and

immediately cleaned up. non9slip surface coating is applied to potential slippery surfaces/ e.g.

steps.

t t!e time of contracting t!e &ork t!e employer of t!e tyre KtterHmec!anic and t!e !ost

employer discuss and agree on !o& t!e !ealt! and safety and supervision of t!e employee &ill be

managed. 8ot! employers take responsibility for t!e safety of t!e tyre KtterHmec!anic and

develop safe systems of &ork t!at &ill apply for t!e duration of t!e :ob


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0ork takes place on a Lat even surface t!at is able to bear t!e general load of t!e ve!icle/ and is

able to bear t!e point load of :acksHlifting e*uipment.


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Conclusion

s a conclusion/ &e !ave learned &!at kind of &ork is done at t!e automotive &orks!op suc! as

servicing ve!icles and moving of !eavy spare parts. T!ere is no &ork t!at is void of !a(ards/ t!us&e !ave listed do&n all t!e !a(ards available and t!e risks associated &it! it. T!roug!out t!e

case study/ it is s!o&n t!at even in a &orks!op/ safety must be taken into account and prioriti(e

it. s t!e saying goes M T!ere is no &ork so urgent t!at it cannot be done safelyN / &e must

al&ays follo& t!e rules and guidelines set by t!e management to avoid any unseen problems and

conse*uences.


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"eerence

1? $5:@@

hse assignment 3 final

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