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Introduction

• A group of 5 students in semester 7 of theBachelor of Mechanical Engineering

(Manufacturing) from the Occupational Safetyand Health (MEM603) class group Aparticipated in an industrial visit to MFORCEBIKE HOLDINGS SDN BHD, which is located at

Bukit Mertajam, Pulau Pinang. The companyspecialized in the assembly of SYM motorcyclesand scooters in Malaysia. SYM is a motorcycle brand from the Sanyang Motor Co. Ltd, a

company based in Taiwan.


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OBJECTIVE

• To design and develop the completeOccupational safety and health program foran industrial organization.

• To apply the theories and knowledge

gained from lecture in an industrialenvironment.


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Part A- Identify the facility for

occupational safety and health that

should exist on the sitePESENTER KHAIRUL NIZAR


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Fire Sprinkler•Discharges water when the effects of a fire

have been detected

Smoke Detector•Smoke detector is a device that sensessmoke, typically as an indicator of fire

During our visit at the SYM Factory, we had observed some safety facilitiesthat are provided by the company. For example:


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Fire extinguisher and Fire hose•Fire and safety equipment

Smoke ventilation system•Remove smoke from a building• Welding smoke and exhaust smoke


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In order to improve the quality of safety at the factory, there are somefacilities 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 toimproper 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.


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The law and regulation on lifting equipment

• Lifting equipment is sufficiently strong and suitable forthe 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.


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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


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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 groundor 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 andinstalling mats can further improve safety and reduce risk of falling.


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Regarding the maintenance program, SYM Factory had

implemented the maintenance and testing of fire safetyequipment. The maintenance and safety are as follows.

• All fire doors and escape routes should be regularlychecked along with associated lighting and signs

• Fire-fighting equipment should be regularly checked• Fire detection and alarm equipment should beregularly checked

• All other equipment provided to help means ofescape arrangements in the building should be

regularly checked• Instructions for relevant employees about testing ofequipment should be available to make sure those who test and maintain the equipment are properlytrained to do so


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For the communication tool, we had observed somecommunication ways that SYM had implemented.

For information distribution:

1. Walkie talkie

• A walkie talkie is a hand held, portable, two way ormulti-way radio transceiver.

• It was used by the supervisors and manager at thecompany to distribute information change and monitor

the operation of the factory.


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2. Production status display board

- Visual communication

- To indicate the workers on the target, ideal and actual

production that should be done.


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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 theoccupants to escape to a safe place

The means for giving warning should be clearly heardand 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.


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PART B- OSH MANAGEMENT SYSTEM

ATPRESENTER MUHAMMAD FAEEZ


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Daily Routine

•Procedure check at the

assembly line.• Workers do self-check.

•Morning talk about safety.


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OSH Documentation

Level 1 Policy and Scope

Level 2 Procedures

Level 3 Work instructions, checklistsand forms

Level 4 Records


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Flowchart of OSH Management

System

Organising

Policy

Planning &Implement

ation

Measuring

Performance

Audit

Reviewing

Perform

ance


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Safety Procedure• Wear appropriate clothes given by

the company.•Focus when working at the

assembly line.

•Supervisors monitoring workers’health and workplace conditions.


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Safety CommitteeCommittee Members:

• Management Representatives

• Employee Representatives

• Co-opted workers & others

Frequency of Meetings• Every Monday, every week.


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Safety Committee Responsibilities:

• Statistics on accident records, ill health, sicknessabsence

• Accident investigations and subsequent action;• Inspections of the workplace by enforcing

authorities, management or employee health andsafety representatives;• Risk assessments;• Health and safety training;

• Emergency procedures; and• Changes in the workplace affecting the health,safety and welfare of employees.


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Awareness/Training• Fire Drill Training.

• Emergency training; First Aid .

• Observing the workplace; Possible harm.

• Operating Machines and Tools.

• How-to assemble motorcycle parts accordingly.


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Inspection Procedure


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Application of PPE

• Gloves Safety Helmets Safety Goggles

• Safety Boot Safety Apron EarProtections


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Notification Warning


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Fire Alarm

Fire Alarm Switch Fire Alarm Bell FireStrobeLight


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Part C-Procedures & activities

need to be carried out in theevent of an

Emergency/injury/accident/

incident PRESENTER MUHAMAD RAZWAN


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FIRE

Figure 1 : Escape Plan ofMFORCE SDN. BHD• Escape Routes

Employer do fire drill at least once per year toensures employees know fire escape plan

All escape routes are clearly marked and approve by fire brigade


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Figure 2 : Fire extinguisher

Fire Fighting

- Small fire

- Fire extinguisher at workplace

-Inspect regularly to keep in good working condition


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Figure 3 : Evacuation plan ofMFORCE SDN BHD

Fire evacuations Assemble at evacuation assembly

pointCheck employees have escaped safely


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FIRE PROCEDURE

Sound fire alarm and alert all workers toevacuate

Alert fire brigade

Leave buiding immediately( escaperoute)

Assemble with other staff at evacuationassembly point

Inform firefighters of the situation


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When an injury or accident is known to have occurred:

• First person nears victim must confirm exact location of the affected andthe 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 ofinjury/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


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• First –aidMinor injuries

Preventing further complications from injury


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PART D - What type of hazards that

may occur and how are they

avoided?PRESENTER AMIRUN NISYAM


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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 musclestrain and also risk of falling due to improperhandling.

b) Workers use fabric gloves while working. Fabric

gloves are slippery which may lead to loss ofgrip while lifting the frames.


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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.


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occur and how are they avoided?▫ Suggestion 2: The use of rubber/synthetic

surfaced gloves reduces the risk of loss of grip.


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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.


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occur and how are they avoided?• Suggestion: The use of PPE headsets can reduce the

stress on the hearing of the workers.


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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/componentsthey are handling

▫ This can be hazardous and also costly

▫ Suggestion: Increase workspace area bypreassembling certain parts outside the mainassembly line


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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/componentsthey are handling

▫ This can be hazardous and also costly

▫ Suggestion: Increase workspace area bypreassembling certain parts outside the mainassembly line.


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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.


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E: COST OF PRACTICING OSH IN

FACILITIES AND COMPARE WITH

DOWNTIME COSTPRESENTER MUHAMAD HAZIQ


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Facilities Costs

Accidential Prevention Cost and Description

Air compressorMotor: 7.5kw / 10hp

Working Pressure (kg/cm²): 12 Bar(Max. 16 Bar)Compressor Speed 850 rpmTank Capacity: 237 LiterCompressor Block PhysicalDimension

(L x W x H): 700mm x 460mm x560mm Weight: 262 kgDimension: 1470mm x 650mm x1150mm

Price: RM 10,600/unit


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Metal table

Price: RM200/unit


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Gas welding (Oxy-Acetylene)Cutting torch dimension: 18”

Price: RM 1,325/set


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Forklift Truck (Toyota)Load capacity: 2000 – 2500 kg

Power: Diesel powered

Price: RM28,000/unit


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Planning costs Accident Prevention Planning costHired OSH officer 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


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Incident costsIncident Consequence Estimated costUsing hand tools Eye damages, cuts and

gashes, strainRM 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,

serious long term illness

RM 10,000.00

Blocked fire exits Difficulties whenincident occur

RM 100,000.00


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Comparison between preventive and

incident costsIncident identification Incident cost Preventive 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 RM 20 000.00 RM 15 000.00

Using hand tools RM 500.00 RM 400.00

Stairs-Frayed Carpet RM 2000.00 RM 9000.00 Slips and trips

At doorways (rain),

spillages

RM 1000.00 RM 500.00

Improperly cleaning chip RM 500.00

RM 200.00


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Conclusion• From the industrial visit, we were able to

understand how Occupational Safety and Health is

applied in the company. Other than that, we werealso able to identify the hazards that are involved inthe manufacturing site and also how the company isable to prevent the hazards from happening.Overall, the company practices safe working

environment, although there are room forimprovements. In conclusion, this visit provided usa better understanding on the use of OccupationalSafety and Health in the workplace.

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