HEALTH

SAFETY AND

ENVIRONMENT
Assignment 3
CASE STUDY OF AUTOMOBILE WORKSHOP
GROUP MEMBERS

: LUQMAN HAKIM BIN ROSLI

CHAN SIN WEI

16098
16173

POR HONG YANG

16148

ABDULQODOS MOHAMMED AL-ORABI

AREZOO SHAHRAZAD
LECTURERS NAME

Table of Content

: DR ABRAR INAYAT

17802

17742

1. Summary
2. Introduction of Case Study
3. Developing risk scenario
4. Justification of the method used
5. Procedure of method
6. Fault Tree Drawing
7. Identifying and assessing all possible risks with hazards
8. Consequences if an accident occurs
9. Method of controlling the risk
10. Solution to minimize risk
11. Conclusion
12. Reference

Summary

In this case study, we will be talking about the various hazards and the risk associated with them
in our industry of interest, automotive workshop. We will be focusing mainly on the workshops
activities such as the type of work for everyday operation and the hazards that come with that
working operation. We will be discussing what kind of hazards a worker is exposed to and the
risks he may face. For this matter, we will use Fault Tree Analysis to create a risk scenario to
better understand the hazards and risks. In addition, we will also be discussing the advantages
and disadvantages of using FTA and look at the procedure of FTA to fully understand it. Finally,
after all the hazards and risks have been identified, we will proceed to discuss the methods and
solutions to rectify the problems.

Introduction to Case Study

We have decided to make automotive factory as our case study for our Health Safety
Environment (HSE) assignment.
In Malaysia, automotive manufacturing has contributed to the nations annual income. This
industry has helped the country make a huge fortune by selling the automobiles locally or
exporting to other countries. Furthermore, the country has also successfully attracted prestigious
automotive brands from overseas such as BMW, Mercedes-Benz and Honda to build their
assemble plants in the country. There are currently 28 automotive companies from overseas to
date. This in turn has created a job opportunity for Malaysians as well as foreign worker to
involve themselves in this industry so as to cater the needs of the rapid-growing industry.
Unfortunately, every year too many people are injured while working in automotive workshops.
Injuries are considered as a menace to the industry as well as for the workers. Workers are
constantly exposed to uncertain hazards that could be life-threatening. According to Labour and
Human Resources Statistics (1998) and (2008), Kuala Lumpur: Ministry of Human Resource,
there are approximately more than 1000 accident scenarios happen each year at automotive
factories in which 30% of them are fatal.
Injuries at automotive factories can be categorised in many forms. For example, manual handling
injuries are the most common type of injury happening at automotive factories. The injuries
occur by handling heavy or awkward objects, heavy lifting, and prolonged or sustained work in
incorrect or awkward postures.
Given the nature of the work there is always the risk of serious injury. Some accidents are
obvious, such as vehicles falling from hoists or jacks, being hit by a passing vehicle while
carrying out roadside work, or tyres exploding during inflation. Other risks are less obvious such
as the long-term effects of breathing asbestos fibres or fumes from solvents and automotive
paints. While there may be risks associated with this type of work, these risks can be avoided.
It is known that every employer have a duty to minimise the risk of injury at their workplace.
This duty is based on guidelines provided by the Workplace OSH Regulations in Malaysia.
These guidelines include Factories and Machinery Act 1967, Employees Social Security Act
1969, Occupational Safety and Health Act 1994. Under these Acts an employer can be held
responsible for the safety of the workshop (workplace), its equipment and its contents, the safety

of the systems of work used by employees and the proper training and supervision of employees
to keep them safe at work. Regulations made under the Act provide additional instruction on how
particular hazards, such as asbestos, hazardous substances, manual handling and plant, are to be
managed. Employees also have their own duty to take reasonable care for their own health and
safety at work and to avoid endangering the health and safety of any other person by anything
they do, or fail to do, at the workplace.
As we know, accidents are avoidable at some costs if necessary safety measures are considered at
the workplace. It is high time that risks at automotive workshops should be minimised to protect
the lives of workers. Making the environment safer is important so that every worker will feel
comfortable while working with hazardous components and machinery. For this assignment, we
hope to develop a risk scenario at the automotive factory and find a solution to minimise the risk.

Developing risk scenario

Various Hazards in Automotive Workshop
As mentioned earlier in the introduction, our project is focused on the events and activities that
happens in automotive workshop. The construction and repair process of automobiles gives a lot
of benefits to mankind but one must not forget the hazard that comes with the job. While the job
scope seemed with increasing work related experience, the hazard faced everyday by the workers
pose a great deal of problem to the worker and surrounding.
Among the hazards that are present in automotive workshop are listed below in their respective
areas
Working with automotive vehicles in the workshop
1) Busy traffic and no exclusion zones or barriers for specified areas or workplaces for cars
and workers.
2) Unsupervised usage of vehicles without clearance within the workshop
3) Unmonitored civilian movement within dangerous area such as near power tools and too
close to vehicle repairing area
4) Vehicle in repair not tied down properly
5) Unmaintained floors of the workshop such as oil spill and uneven or cracked floor
6) Unsafe work conditions such as working near highly flammable or harmful chemical
materials
7) Usage of power tools and equipment without certificate of competency

Usage of lifting equipment

1) Usage of damaged or uninspected vehicle hoists
2) Unmaintained hydraulic and trolley jacks. No vehicle stands used when vehicle is raised
by hydraulic jack
3) Unsecured vehicle ramps which may cause vehicle movement

Storage and Racking of Parts

1)
2)
3)
4)

Unbalanced and tyres stacked too high which has a high chances of tyres falling
Tyre or parts storage racking above shoulder height
Unsecured ladders to pick up parts
Tyres or heavy equipment lifted or moved by hand instead of assisting equipment

Handling of heavy parts

1) Engines that needs to be replaced are removed without calculations on the strength of
supporting equipment
2) Parts are removed without handling aids
Risk Scenario
All the hazards that are commonly meet during the working period inside the workshop have
been listed beforehand. To better understand all the hazard listed, it is best we see how they relate
to each other. Below is a risk scenario developed by using fault tree analysis.
Top event Serious Personnel Injury: in all working experience, we take precaution to avoid
getting injured at work.
First case serious personnel injury can come in many factor, one of them is with an accident
with a repair vehicle. Normally, a repair vehicle requires that it be hoisted up in order to access
the lower part of the vehicle but sometimes the vehicle can move or slip thus resulting in an
accident between the vehicle and the worker. The slipping can come from 2 factor, either the
handbrake of the vehicle was turned off or the chocks for the wheels are damages. Accident with
the repair vehicle can also come from external factor such as an unsupervised driving from
civilian into the work area which is caused by confusion of the customer. When there is no
specific waiting area for the customer to drop off his or her vehicle, she or he might drive into
the workshop without supervision resulting in an accident

Second case serious personnel injury can also come from a simple case of tripping while
working. The main reason from tripping is from an oil spill which was left alone without any
cleaning or covering. This result in a high chance of slipping in which the worker might slip and
fall

Third case the least probable event in which a worker could get hurt is if she or he carries
heavy parts of the vehicle without any handling aid. As the parts are sometimes very heavy, for
example the engine, the weight might be too much too bear and can result in dropping and hitting
a worker.

Method to develop the risk scenario

As mentioned earlier, we have developed a risk scenario from all the hazards that have been
identified in the workshop. However, to develop a good and efficient risk scenario is difficult if
the methods to create them are not used. To develop a risk scenario, we can either use Fault Tree
Analysis, Event Tree or HAZOP. For our risk analysis, we have chosen the Fault Tree Analysis.
What is a Fault Tree Analysis?
Fault Tree Analysis or FTA in its simplicity is a top down approach starting with the unwanted
consequences as the top event and identifying all possible factors that could contribute to the top
event. FTA is a failure analysis technique, it involves examining preceding events that leads up to
the top event which is a normally a system failure. FTA are deductive method for identifying
ways in which hazards can lead to an accident.

The procedure of developing the fault tree is shown below.

Fault Tree Analysis
1. Determine the most undesirable event which is considered the Top Event. The Top Event
must only be one.
2. From the Top Event, we must determine the events that contribute to it. The number of
contributing events can be as many as possible.
3. From the contributing event that causes the Top Event, we must identify the relationship
between them in terms of AND and OR gates.
4. If there are any events that leads to the contributing events, which are called Basic
Events, it must also be listed in the Fault Tree. The Basic Events can be as many as
possible.
5. The relationship between the Basic Events and the contributing events must also be
identify.

There are many uses for FTA, below are some of them

Understanding the logic leading to the top event

Prioritizing the contributing events that causes the top event
To assist in designing a more efficient system
As a diagnostic tool to identify and correct causes of the top event

Justification of the method

Why do we use FTA to create the risk analysis? The answer is simply because the advantages of
using it is more than the disadvantages.

Advantages of FTA

It is very simple to understand at first glance and the contributing events that can be
easily interpreted.
It can be used to show multiple failures or combinations of failures that leads to the top
event.
The path that leads to the top event can easily be seen and rectified.
The path generated is easily understood by workers to avoid doing the events.

Disadvantages of FTA

To understand the events require deep knowledge of the system and the work situation
Not practical on systems with large numbers of safety critical failures.
The path can grow to become very complex.

As listed above, it can be seen that a FTA risk analysis is best for a workshop environment due to
the fact that there are not much safety critical failures as the hazards are simple and the FTA will
not be complex due to the simplicity of the working environment in the workshop. The path
developed is easy enough for all the workers to understand at first glance and it has covered over
90% of the possible risks and hazards. Finally, the workshop environment does not rely too
heavily on machinery until it poses a threat rather human error which is most of the times can be
rectify before things get out of hand

Fault Tree Drawing

Serious Personal
Injury
AN
D

Accident with a
Repair Vehicle
Tripping while
Working
O

Slipping of
Vehicle

Unsupervised
Driving

Oil Spill on
the Floor

O
No
Specific
Waiting
Area

Handbrak
e Turn Of

Choke for
Wheels
Justification
Damage

of the method

Carry Heavy
Parts of
Vehicle

Why do we use FTA to create the risk analysis? The answer is simply because the advantages of
using it is more than the disadvantages.

Advantages of FTA

It is very simple to understand at first glance and the contributing events that can be
easily interpreted.
It can be used to show multiple failures or combinations of failures that leads to the top
event.
The path that leads to the top event can easily be seen and rectified.
The path generated is easily understood by workers to avoid doing the events.

Disadvantages of FTA

To understand the events require deep knowledge of the system and the work situation
Not practical on systems with large numbers of safety critical failures.
The path can grow to become very complex.

As listed above, it can be seen that a FTA risk analysis is best for a workshop environment due to
the fact that there are not much safety critical failures as the hazards are simple and the FTA will
not be complex due to the simplicity of the working environment in the workshop. The path
developed is easy enough for all the workers to understand at first glance and it has covered over
90% of the possible risks and hazards. Finally, the workshop environment does not rely too
heavily on machinery until it poses a threat rather human error which is most of the times can be
rectify before things get out of hand

Identifying and assessing all the possible risk with hazards

What are the hazards?

Who might be harmed

and how?
Skin contact over a
long period can lead
to severe dermatitis
and skin cancer.

What are you already doing?

Car engine running

inside, toxic exhaust
fumes, eg carbon
monoxide

The fumes may cause

eye irritation and
breathing difficulties.

Car exhaust attached to extractor system when

engine is running
Extractor system maintained and tested to
prevent leaks

Fire
Petrol and LPG fires

If trapped workers
and customers could
suffer fatal injuries
from smoke
inhalation/ burns.

Fire alarms maintained and tested by

manufacturer
Extinguishers provided and inspected under
contract
Special fire exits not needed as all work areas
have immediate access to outside
Fuel retriever used to empty vehicle fuel tanks
outside
Spillages cleared immediately
Component cleaning in re-circulating paraffin
system, not petrol
LPG fuelled vehicles ported in safe places
Workers trained in hazards of LPG
Fire risk assessment has been done, and any
necessary action taken, see
www.gov.uk/workplace-fire-safety-yourresponsibilities

Battery charging

Workers could suffer

burns from contact
with battery acid
while charging,
particularly if battery

Proprietary charger, installed by electrician, is

used in accordance with instructions
Acid-resistant gloves and goggles supplied and
used

Hazardous substances
Contact with used
engine oil etc during
servicing

Nitrile gloves supplied and used

Garage overalls supplied and used
Contract for regular cleaning of overalls
Workers informed to clean hands thoroughly
and use skin creams provided after contact with
hazardous substances

is overcharged and
explodes.
Electrical equipment
Portable appliances,
eg hand lamps.

Workers could get

electrical shocks or
burns from faulty
electrical equipment
or on installation.
Electrical faults can
also lead to fires.

Mechanical
equipment Use of
grinding equipment

Workers may suffer

serious injury from
unguarded moving
parts of machinery.
Workers can also get
cut on sharp edges or
scald themselves on
hot parts.

Falling objects
Car lift failure or car
jack failure

Failure of a car lift,

jack or other lifting
equipment may cause
severe crush injuries
to an employee.

Low voltage 24 V hand lamps used

Residual current device (RCD) built into main
switchboard.
A few 240 V tools are used. All have industrial
plugs and leads
Testing carried out annually on all portable
240 V tools and workers are trained to carry out
pre-use visual checks and report defects
Safety checks of the electrical equipment and
installations are carried out to ensure that
equipment continues to be safe. Where necessary
this is done by a competent electrician

All mechanical equipment checked before use

and faults reported to supervisor
Equipment not to be left running unattended
Guarding provided
Ear defenders and safety goggles provided and
worn.
Grinding wheels changed by trained person
Car lifts and jacks serviced by supplier and
inspected by insurers every 6 months
Jacks only used where ground conditions are
firm, stable and level. Once vehicle lifted, axle
stands used Axle stands regularly maintained
and inspected
Safe working loads not exceeded

Work involving air

conditioning systems

Workers could suffer:

frostbite through
skin or eye contact
with refrigerant liquid
or gas asphyxiation
if sufficient
quantities of gas
escape into confined
space
exposure to harmful
gases through
thermal
decomposition of
refrigerant if exposed
to a naked flame.

Workers are trained in correct procedures

Compressed air
Explosion of
equipment tyres

Workers could suffer

blast injuries from
tyre or equipment
explosion. Workers
could suffer damage
to internal organs if
air is introduced into
the body.

All workers trained in safe working procedures

and dangers of horseplay
Airline has deadmans handle
System inspected and serviced every year by
insurers

Handling vehicle air

bags

Air bags could

explode when not
fitted, causing injury.

Units are stored in suitable cabinet of their

own
Workers are trained in correct handling and
fitting Faulty units are returned to supplier for
disposal

Manual handling
Movement of
components

Workers risk injuries

or back pain or pain
elsewhere from
handling heavy and/or
bulky objects.

Workers are trained in safe manual handling

and to ensure contractors follow safe manual
handling techniques
Manual handling aids are available, eg lift
truck

Vehicle movements

Workers and
customers risk
potentially serious
injury if struck by a
moving vehicle

Safe parking provided for customers without

need for reversing
Marked walkways for pedestrians
Vehicles driven slowly around premises
Workers ensure that cars being manually
pushed always have a person seated at the wheel,
to keep the vehicle under control

Slips and trips

Doorways (rain),
spillages, uneven
surfaces
Workers and
customers may be
injured if they trip
over objects or slip on
spillages, eg oil or
water.

Good housekeeping standards maintained

through training and monitoring
Floors degreased weekly
Absorbent granules and sawdust put on spills
as soon as possible
Entrances and exits maintained

Working at height

Falls from any height

can cause bruising
and fractures and
potentially serious
injuries.

Appropriate access equipment is provided for

work on trailers and tops of commercial vehicles
Handrails fitted at edges of raised storage
areas and access stairway provided
Workers are competent to use ladders where
appropriate
Vehicle inspection pits clearly marked and
covered when not in use

Method of controlling the risk

1: Do not rely on safe behavior as the main means of preventing injury Safety solutions that rely
on administrative controls such as training, supervision, and procedures, require constant
vigilance and effort to maintain. Physical changes such as improved workplace layout do not
require the same level of effort and are more effective and a sustainable means of injury
prevention.
2: Use mechanical devices to reduce heavy lifting, awkward postures, sustained postures and
other body stressing Many mechanical devices are already in use, such as tools powered by
compressed air, hoists, cranes and lifting hooks,bead breakers,and body under slides to get under
vehicles. Some devices are widely known but used less often, such as vacuum lifters for
windscreen insertion,using hoists when detailing,hip-height roller conveyor and ramps to load
and move tyres, order picking ladders with load tables for stock access, pads and body tables for
comfortable work in footwells and under dashes and castors on heavy toolboxes. A few
workplaces apply innovative ideas such as tyre under slide and using overhead-mounted body
support harnesses for work over the engine bay. If the equipment exists to reduce the risk of body
stressing then it should be purchased and used.
3: Search widely for solutions and challenge thats the way it has always been done
Because people do not expect to go home injured or maimed from work, what people accept as
the normal way of doing things has changed. Managers, owners and employees need to
recognize this. For example, for working safely with axle stands and jacks the Australian
Standards are the reasonable best starting point, however some automotive workshops do not
apply the safety standards in these document.

Solution to minimize the risk

Lower risk for managing traffic in workplace:
Documented traffic management plan and signage which does not permit customers to drive their
vehicle within a workshop, e.g. customer service area for vehicle drop-off employee moves
vehicle out of workshop and into customer car park/pick up area.
Lower risks on work area:
Vehicle traffic is physically segregated from service personnel and pedestrians.
Lower risks on driving vehicle:
Employees drive within their license and competency.
When working on trucks, trailers, earth moving equipment or farm vehicles vehicle dropped off
and moved to designated repair area by licensed operator with appropriate experience.
Lower risks on preventing vehicles from moving:
Vehicle is prevented from moving by using three of these methods
Keys are removed from the ignition
The hand brake is on
Wheels are chocked on both sides of the vehicle using serviceable purpose-built chocks
Vehicle raised on a pillar hoist with all wheels off the ground.
Lower risks for preventing slips and trips:
All leads are stored out of the way, e.g. retractable reels. Power and pneumatic outlets located
close to the service area. Spills, including water spills, are covered with absorbent material and
immediately cleaned up. A non-slip surface coating is applied to potential slippery surfaces, e.g.
steps.
Lower risks on Managing the safety of the employee on service calls to other workplaces:
At the time of contracting the work the employer of the tyre tter/mechanic and the host
employer discuss and agree on how the health and safety and supervision of the employee will be
managed. Both employers take responsibility for the safety of the tyre tter/mechanic and
develop safe systems of work that will apply for the duration of the job

Lower risks on Conditions at the work location:

Work takes place on a at even surface that is able to bear the general load of the vehicle, and is
able to bear the point load of jacks/lifting equipment. Lighting is sufficient that detail work (such
as reading gauges) can be readily carried out. Other risks are assessed and controlled, e.g.
Site/vehicle condition
Presence of dangerous chemicals or equipment
Electrical safety, e.g. overhead cables. Procedures are in place and used that require vehicles to
be relocated, e.g. towed, to a safe location.
Finally the best solution to reduce hazards and accidence around workplace at the workplace is
that employees and employers follow the structures and care about safety first.

Conclusion
As a conclusion, we have learned what kind of work is done at the automotive workshop such as
servicing vehicles and moving of heavy spare parts. There is no work that is void of hazards, thus
we have listed down all the hazards available and the risks associated with it. Throughout the
case study, it is shown that even in a workshop, safety must be taken into account and prioritize
it. As the saying goes There is no work so urgent that it cannot be done safely , we must
always follow the rules and guidelines set by the management to avoid any unseen problems and
consequences.

Reference
1. http://www.dir.ca.gov/dosh/etools/09-031/HazAssessCheck.pdf
2. http://www.commerce.wa.gov.au/worksafe/PDF/Codes_of_Practice/Safeguardi
ng_of_machinery_and_plant.pdf
3. http://www.worksafe.vic.gov.au/__data/assets/pdf_file/0015/10293/automotive
_workshop_safety.pdf