FAKULTI PENDIDIKAN DAN BAHASA

SEMESTER SEPTEMBER / 2012

OUMH 2203 ENGLISH FOR WORKPLACE COMMUNICATION

NAMA PELAJAR NO. MATRIKULASI NO. KAD PENGNEALAN NO. TELEFON E-MEL
PUSAT PEMBELAJARAN

: : : : :
:

LIM POH TIN 650723015148002 650723-01-5148 016-7189793 ptlim9793@yahoo.com

INSTITUT PERGURUAN TUN HUSSEIN ONN

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CONTENT 1.0 2.0 Introduction Content 2.1 Present Situation 2.2 Problem 2.3 Solution 2.3.1 Improvement of Storage Personnel Employees. 2.3.4 Provide a Slip,Trips and Falls Checklist/ Manual Handling Checklist/Electrical Checklist 8-13 13 3.0 Conclusion 3.1 Evaluation of changes 3.2 Recommendation 4.0 References 14 14-15 16 2.3.5 Provide Training on Lifting Techniques for Employees 7 7 7-8 2.3.2 Manual Processes On the Experience and Knowledge of 2.3.3 Provide Training On How to Operate the Equipment for 5 5-6 4-5

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A Standard Report To Improve Safety In The Factory

Prepared for Alvin Wong , Managing Director The Fortune Textile Industrial Jalan Tanjung Laboh, 83000 Batu Pahat By Lim Poh Tin Factory Manager The Fortune Textile Industrial Jalan Tanjung Laboh, 83000 Batu Pahat 10 November 2012

To

Alvin Wong, Managing Director Lim Poh Tin, Factory Manager 10 November 2012

From : Date :

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Subject

: A Standard Report To Improve Safety In The Factory

1.0 INTRODUCTION As an Occupational Health manager of the factory, I had a tour to the factory the past few days. While I was looking at the Material and Handling department, I discovered that the operators of that department didnt abibe the safety regulations as stipulated. They were ignoring the safety regulations at their work. Handling and storing materials involves diverse operations such as storage of corrosive chemicals , presence of large quantities of dry fabric or paper can increase the risk and spread of fires. The efficient handling and storing of materials is important to industry. These operations provide a continuous flow of raw materials, parts, and assemblies through the workplace, and ensure that materials are available when needed. Yet, the improper handling and storing of materials can cause costly injuries. Nowadays, machiner have become larger, speedier and more sophiscated and they also introduced now potential hazards. As workers have to cope with mechanization and the demand for increasing productivity, work stress, largely unrecognized or ignored, exerted an increasing influence on their well being. Environmental concern raised by the textile industries stem from two sources, the processes involved in textile manufacturing and hazards associated with the way the products are used. Therefore, the workers encounter various types of factory accidents or health danger due to lack of proper safety rules. I wrote this report to you with the purpose to propose a permanent solution that prevents recurrence of the actual causes of hazards in the factory. Management is rmly committed to a policy enabling all work activities to be carried out safely, and with all possible measures taken to remove (or at least reduce) risks to the health, safety and welfare of employees, contractors, authorised visitors, and anyone else who may be affected by our operations. We are committed to ensuring we comply with the Workplace Health and Safety Act 1995, the Workplace Health and Safety 4

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Regulations 1998 and applicable codes of practice and Malaysian Standards as far as possible.

2.0 CONTENT 2.1 Present Situation 1 The housekeeping aspect in the Material and Handling department is controlled by a crew of middle-aged women. 2 3 Workers dealing with the dyeing of materials are wearing slippers. The switchboards and electrical equipment in that department is in charged by an in-experience supervisor who is a twenty-eight-year man. Everything on the switchboard are not clearly labelled. The safety switches (residual current devices) have not been tted to all circuits. 4 During mechanically moving materials, the workers overload the equipment not according the weight, size and shape of the materials or moved dictate the type of equipment used for transporting them . 5 The steam pipes are leaking because they are worn-out.

2.2 Problem 1 The walkways and doorways in the factory are fulled of boxes, extension cords and litter even at the stairways.There are also stacked up with boxes. Nobody is responsibility for cleaning the oors, clearing work areas and walkways. The workers have no adequate space to enable ease of movement. The tread on stairs are not adequate to minimise slipping too. Employees expose to many potential hazards like moving industrial equipment or slick areas. A hazard is something that can cause harm if not controlled. The outcome is the harm that results from an uncontrolled hazard.

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These can cause crush injuries, lacerations, bruising, sprains and strains to the part of the body that is hit or trapped. In case of a dangerous situation such as fire, the workers will not be able to escape quickly. 2 Improper storage of dyes, chemicals and other auxiliaries. Exposure to chemicals and certain reactive, vat and disperse dyes can cause skin irritation. 3 There is no evaluation on the ability of the workers during the handling materials. The main risk in the factory is usually associated with individual capabilities. Here comes the fact that the strength, skill and disposition vary from one person to another. A certain task may be perceived in many different ways such that the effects of the task change in terms of intensity and gravity for each employee. 4 Not all material can be manually lifted. Carts, bins, hand trucks, dollies, and fork lifts are all mechanical aids that can only help transport a load without putting undue strain on the back. Pushcarts and bins only can be useful for light, awkward material handling tasks, while hand trucks and forklifts just can help to move heavier, stackable material. Our factory is lack of mechanical aids for loading the heavier materials. 5 The Material and Handling department is shortage of well-trained staff especially in mechanically moving materials. The worst situation that happened frequently is the workers havent gain access typically to perform maintenance or to replenish supplies or raw materials (ink, oil, water, or toner). They always made mistake to replenish supplies or maintenance of machinery.

2.3 Solution 2.3.1 Improvement of Storage Stored materials must not create a hazard. Storage areas must be kept free from accumulated materials that may cause tripping, fires, or explosions, or that may contribute to the harboring of rats and other pests. When stacking and piling 6

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materials, it is important to be aware of such factors as the materials' height and weight, how accessible the stored materials are to the user, and the condition of the containers where the materials are being stored. All bound material should be stacked, placed on racks, blocked, interlocked, or otherwise secured to prevent it from sliding, falling, or collapsing. A load greater than that approved by a building official may not be placed on any floor of a building or other structure. Where applicable, load limits approved by the building inspector should be conspicuously posted in all storage areas. Dyes, chemicals and other auxiliaries should be stored in a separate work area and access to this area should be limited to trained personnel. The storage area should be kept relatively cool and dry and all items must be recorded in a log book and clearly labelled. Internationally recognized symbols should be used and all factory workers should be train to recognize them. The storage areas, balances and all utensils should be kept clean for safety reasons and to avoid cross contamination.

2.3.2

Manual Processes On the Experience and Knowledge of Personnel The effective identification of hazards and controls can vary widely in manual processes depending on the experience and knowledge of personnel. Make sure the workers have the skills for the job. The new workers must be provided with, in addition to the information required or relevant comprehensible information as to the safety and health risks and the preventive and protective measures taken with respect to those manual handling operations. When there is a new worker, we should introduce them to the workplace: the facilities, their fellow workers, work times and meal breaks. This is only an induction. In an induction, we must also tell the workers how to work safely and how to report a problem, incident or injury. It is a good idea to formalise the inductions and structure them in a way we can keep track of.

2.3.3

Provide Training On How to Operate the Equipment for Employees.

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To reduce potential accidents associated with workplace equipment, employees need to be trained in the proper use and limitations of the equipment they operate. This includes knowing how to effectively use equipment such as conveyors, cranes, and slings. To ensure that our staffs have sufficient knowledge to handle the machines or equipment, the management needs to prepare a standard training manual for all the relevant staff. We should recommend using a formal training program to reduce materials handling hazards. Instructors should be well-versed in matters that pertain to safety engineering and materials handling and storing. The content of the training should emphasize those factors that will contribute to reducing workplace hazards including the following:

Alerting the employee to the dangers of lifting without proper training. Showing the employee how to avoid unnecessary physical stress and strain. Teaching workers to become aware of what they can comfortably handle without undue strain. Instructing workers on the proper use of equipment. Teaching workers to recognize potential hazards and how to prevent or correct them.

Because of the high incidence of back injuries, safe lifting techniques for manual lifting should be demonstrated and practiced at the work site by supervisors as well as by employees. 2.3.4 Provide Slip,Trips and Falls Checklist / Manual Handling Checklist/ Electrical Checklist . Slip,Trips and Falls Checklist Slips, trips and falls account for nearly a quarter of workplace injuries. We must ensure that the workplace is kept free of hazards that cause these injuries, and this checklist will help us do that. We should involve the workers in lling out this checklist. The sample of Slip,Trips and Falls Checklist as the following:

( SAMPLE ) SLIPS, TRIPS AND FALLS CHECKLIST

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Date checklist completed: _______________________________________________ Date checklist to be reviewed:____________________________________________ (annually or when there is a change or addition to procedures or workplace set-up) Name of person who completed checklist:__________________________________ Position title: ____________ Company/workplace: ____________

Floors Are oors free of water, ice, oil or other uids? Yes Yes Are ramps designed to prevent slips and falls? Housekeeping Are walkways and doorways clear of boxes, extension cords and litter? Are spills cleaned up immediately? specied? Stairs Are stairways kept clear of boxes, extension cords and litter? Is the tread on stairs adequate to minimize slipping? Is the tread on each stair adequate? Are hand-rails adequate? Lighting Are work areas, walkways and stairs well lit? Yes Yes Footwear Is the footwear worn by workers suitable for the workplace? Yes No No No Does the lighting enable workers to move between indoor and outdoor tasks safely? ______________________________________________________________________ Yes Yes Yes Yes No No No No Yes Yes Yes No No No Yes No No No Are oor surfaces even ( e.g. no loose tiles or carpet that is torn or has ridges or holes)?

______________________________________________________________________

Are the responsibilities for cleaning oors, clearing work areas and walkways clearly ______________________________________________________________________

______________________________________________________________________

Manual Handling Checklist 9

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Manual handling is a component of many work tasks. It involves repetitive movements , lifting and carrying loads or even sedentary tasks such as using a computer. Manual handling is a major factor in workplace injuries. This checklist will help us to address the manual handling issues in the workplace and reduce the risk of injuries due to manual handling. We should involve our workers in lling out the checklist. The sample of Manual Handling Checklist as the following:

( SAMPLE ) MANUAL HANDLING CHECKLIST Date checklist completed: ________________________________________________ Date checklist to be reviewed: ____________________________________________ (annually or when there is a change to the workplace) Name of person who completed checklist:___________________________________ Position title: _____________ Work tasks Can all materials be lifted and carried easily? Yes Yes Yes No No No Are mechanical aids (such as trolleys and hoists) available and used? Are workers trained in manual handling techniques and the use of mechanical aids? ______________________________________________________________________ Work equipment Are work benches a comfortable height? Yes Yes strain? Yes No No No Are chair backs and seat heights adjustable? Is ofce equipment (such as computer keyboards and screens) adjusted to avoid body Company/workplace: _______________ ______________________________________________________________________

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Are storage shelves organized to minimize bending and stretching? Yes No _____________________________________________________________________ Work organization Are tasks rotated to avoid repetitive work? Yes Yes Yes No No No Is work planned to balance out periods of high and low demand? Are workers able to take adequate breaks? _____________________________________________________________________ Work area Do workers have adequate space to enable ease of movement? Yes Yes No No Are items that are regularly-used within easy reach? Is there sufcient area around machines or equipment to enable access for maintenance and repair? Yes No

Electrical Checklist Electricity has the potential to seriously injure and kill. As electricity is invisible, it is even more dangerous. As the manager of a small business, we are responsible for ensuring the electrical ttings and electrical equipment in the workplace is safe, and inspected and maintained regularly. We should involve our workers in lling out the checklist. The sample of electrical checklist as the following:

______________________________________________________________________ ( SAMPLE ) ELECTRICAL CHECKLIST Date checklist completed: ________________________________________________ 11

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Date checklist to be reviewed:_____________________________________________ (annually or when there is a change in the electrical equipment or an electrical incident) Name of person who completed checklist:___________________________________ Positiontitle:________________ Company/workplace:________________

Electrical switchboards and equipment Are switchboards and electrical equipment in a safe condition? Yes No Is everything on the switchboard clearly labeled? Yes No Have safety switches (residual current devices) been tted to all circuits? ______________________________________________________________________ Power points, light ttings and switches Are all power points, light ttings and switches in a safe place and free from obvious defects (e .g. loose covers or wires, broken or damaged ttings, signs of overheating)? Yes No Are isolating switches clearly labeled and accessible? Yes No ______________________________________________________________________ Power tools, exible leads and power boards Is portable electrical equipment protected by safety switches? Yes No Are all power tools, extension leads and power boards maintained in a safe operating condition (check for damaged insulation, water leaks, burn marks, bent or loose pins or ttings)? Yes No Are extension leads and power boards located in a safe position to prevent mechanical or other damage (including trips)? Yes No _____________________________________________________________________ Inspecting and maintaining electrical equipment Are all electrical ttings and electrical equipment, including portable power tools, regularly inspected and maintained? Yes No Have all the power leads been inspected and tagged? Yes No 12

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*For specialized advice about electrical safety, contact a licensed electrical contractor.

Make sure all power points, light ttings and switches are in a safe place and free from obvious defects .We should check for damaged insulation, water leaks, burn marks, bent or loose pins or ttings. Always get a licensed electrical contractor to check our electrical switchboards and equipment in the factory. Inspecting and maintaining electrical equipment regularly are needed in order to prevent workers electrocution incident. A significant contribution to safety in the factory can be made by personnel being dressed appropriately.

2.3.5

Training for Lifting Techniques Because of the high incidence of back injuries, safe lifting techniques for manual lifting should be demonstrated and practiced at the work site by supervisors as well as by employees. A training program to teach proper lifting techniques should cover the following topics: Awareness of the health risks to improper liftingciting organizational case histories. Knowledge of the basic anatomy of the spine, the muscles, and the joints of the trunk, and the contributions of intra-abdominal pressure while lifting. Awareness of individual body strengths and weaknessesdetermining one's own lifting capacity. Recognition of the physical factors that might contribute to an accident, and how to avoid the unexpected. Use of safe lifting postures and timing for smooth, easy lifting and the ability to minimize the load-moment effects. Use of handling aids such as stages, platforms, or steps, trestles, shoulder pads, handles, and wheels. Knowledge of body responseswarning signalsto be aware of when lifting.

3.0 CONCLUSION

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3.1. Evaluation of the Changes 3.1.1 Factories rely on employees to perform a task or duty that is one-step in the process for manufacturing. With the quality control procedure our company will enjoy a good reputation in Textile Industrials. 3.1.2 With the Safety Standards that have improved, the staffs will be working under a safe environment. They wont be stressful all the time throughout the working days. 3.1.3 With the well-trained staffs, our productivity will be increased to our expectation in order to get more profits. 3.1.4 After carrying out the well-planed storage, the employees will be able to work in a systematically arranging materials workplace. 3.2. Recommendation 3.2.1 We shall implement a quality control system to monitor and verify our internal quality control. 3.2.2 A licensed electrical contractor to check our electrical switchboards and equipment in the factory is needed. 3.2.3 The management should provide rubber boots to workers in the olyeing department so as to reduce the risk of falls as the floor is wet all the time. Workers dealing dyestufts or chemicals should be provided with glover and facial masks to aviod coming in contact which can cause serious skin problems. 3.2.4 Persons appointed by branch manager shall jointly responsible to conduct the evaluation. The work flow for the manual handling evaluation is as follow:

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Work Flow for the Manual Handling Evaluation Potential Staffs

Evaluated by Assessors Evaluation Not qualify Re-trained Results

Persons appointed by branch manager

Transfer to another department suitable for the staff

Or

Evaluation Report

Approval by Branch Manager

Register in Approved List. (Keep in Management Department)

Review performance annually & update into Potential Staffs List

3.2.4

Mr. Selva from the Materials and Handling Department who had attended Handling Management Course last year and he also had 8 years experiance in a textlie firm. He would be the best person to prepare the training manual for inspection, handling and preservation and conduct trainning for all the relevant staffs as well.

( 2754 words )
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REFERENCES
H & S Executive (2002) COSHH A Brief Guide to the Regulations What You Need to Know About the Control of Substances Hazardous to Health Regulations. Badger, I. (2003). English for work: Everyday business English. UK :Pearson Education Limited. Jaya Poshani Ponnudurai.(2010). English for Workplace Communication: Business Reports.Selangor. Meteor Doc. Sdn. Bhd.

WEBSITE
1 2 3 http://www.osha.gov/doc/outreachtraining/htmlfiles/mathan.html http://www.ehow.com/about_5176090_problems-textile industry.html#ixzz2ANnWTCvo http://en.wikipedia.org/wiki/Occupational_safety_and_health

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