MEM 603 CASE STUDY

MFORCE BIKE HOLDINGS SDN.

BHD.

Introduction
A group of 5 students in semester 7 of the
Bachelor of Mechanical Engineering
(Manufacturing) from the Occupational Safety
and Health (MEM603) class group A
participated in an industrial visit to MFORCE
BIKE HOLDINGS SDN BHD, which is located at
Bukit Mertajam, Pulau Pinang. The company
specialized in the assembly of SYM motorcycles
and scooters in Malaysia. SYM is a motorcycle
brand from the Sanyang Motor Co. Ltd, a
company based in Taiwan.

OBJECTIVE
To design and develop the complete
Occupational safety and health program for
an industrial organization.
To apply the theories and knowledge
gained from lecture in an industrial
environment.

Part A- Identify the facility for

occupational safety and health that
should exist on the site
PESENTER KHAIRUL NIZAR

During our visit at the SYM Factory, we had observed some safety facilities
that are provided by the company. For example:
Fire Sprinkler
Discharges water when the effects of a fire
have been detected
Smoke Detector
Smoke detector is a device that senses
smoke, typically as an indicator of fire

Fire extinguisher and Fire hose

Fire and safety equipment
Smoke ventilation system
Remove smoke from a building
Welding smoke and exhaust smoke

In order to improve the quality of safety at the

facilities that could be provided or improved by
1. LIFTING EQUIPMENT
- The frames were lifted by had from the trolley
This can increase muscle strain and also risk of
improper handling.
Recommendation

factory, there are some

the SYM Factory.
to the assembly line.
falling due to

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.

The law and regulation on lifting equipment

Lifting equipment is sufficiently strong and suitable for
the 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.

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

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 ground
or 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 and
installing mats can further improve safety and reduce risk of falling.

Regarding the maintenance program, SYM Factory had

implemented the maintenance and testing of fire safety
equipment. The maintenance and safety are as follows.
All fire doors and escape routes should be regularly
checked along with associated lighting and signs
Fire-fighting equipment should be regularly checked
Fire detection and alarm equipment should be
regularly checked
All other equipment provided to help means of
escape arrangements in the building should be
regularly checked
Instructions for relevant employees about testing of
equipment should be available to make sure those
who test and maintain the equipment are properly
trained to do so

For the communication tool, we had observed some

communication ways that SYM had implemented.
For information distribution:
1. Walkie talkie
A walkie talkie is a hand held, portable, two way or
multi-way radio transceiver.
It was used by the supervisors and manager at the
company to distribute information change and monitor
the operation of the factory.

2. Production status display board

- Visual communication
- To indicate the workers on the target, ideal and actual
production that should be done.

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 the
occupants to escape to a safe place
The means for giving warning should be clearly heard
and 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.

PART B- OSH MANAGEMENT SYSTEM

AT
PRESENTER MUHAMMAD FAEEZ

Daily Routine
Procedure check at the
assembly line.
Workers do self-check.
Morning talk about safety.

OSH Documentation
Level 1
Policy and Scope
Level 2
Procedures
Level 3
and forms
Work instructions, checklists
Level 4
Records

Flowchart of OSH Management

System
Policy
Organisi
ng
Audit
Planning &
Implement
ation
Measuri
ng
Perform
ance
Reviewin
g
Perform
ance

Safety Procedure
Wear appropriate clothes given by
the company.
Focus when working at the
assembly line.
Supervisors monitoring workers
health and workplace conditions.

Safety Committee
Committee Members:
Management Representatives
Employee Representatives
Co-opted workers & others
Frequency of Meetings
Every Monday, every week.

Safety Committee Responsibilities:

Statistics on accident records, ill health, sickness
absence
Accident investigations and subsequent action;
Inspections of the workplace by enforcing
authorities, management or employee health and
safety representatives;
Risk assessments;
Health and safety training;
Emergency procedures; and
Changes in the workplace affecting the health,
safety and welfare of employees.

Awareness/Training

Fire Drill Training.

Emergency training; First Aid .
Observing the workplace; Possible harm.
Operating Machines and Tools.
How-to assemble motorcycle parts accordingly.

Inspection Procedure

Application of PPE
Gloves
Safety Boot
Protections
Safety Helmets
Safety Apron
Safety Goggles
Ear

Notification Warning

Fire Alarm
Fire Alarm Switch
Fire Alarm Bell
Fire
Strobe
Light

Part C-Procedures & activities

need to be carried out in the
event of an
Emergency/injury/accident/
incident
PRESENTER MUHAMAD RAZWAN

FIRE
Figure 1 : Escape Plan of
MFORCE SDN. BHD
Escape Routes
Employer do fire drill at least once per year to
ensures employees know fire
escape plan
All escape routes are clearly marked and approve
by fire brigade

Figure 2 : Fire extinguisher

Fire Fighting
- Small fire
- Fire extinguisher at workplace
-Inspect regularly to keep in good
working condition

Figure 3 : Evacuation plan of

MFORCE SDN BHD
Fire evacuations
Assemble at evacuation assembly
point
Check employees have escaped safely

FIRE PROCEDURE
Sound fire alarm and alert all workers to
evacuate
Alert fire brigade
Leave buiding immediately( escape
route)
Assemble with other staff at evacuation
assembly point
Inform firefighters of the situation

When an injury or accident is known to have occurred:

First person nears victim must confirm exact location of the affected and
the 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 of
injury/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

 First aid
Minor injuries
Preventing further complications from injury

PART D - What type of hazards that

may occur and how are they
avoided?
PRESENTER AMIRUN NISYAM

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 muscle
strain and also risk of falling due to improper
handling.
b) Workers use fabric gloves while working. Fabric
gloves are slippery which may lead to loss of
grip while lifting the frames.

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.

D. What type of hazards that may

occur and how are they avoided?
Suggestion 2: The use of rubber/synthetic
surfaced gloves reduces the risk of loss of grip.

D. What type of hazards that may

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.

D. What type of hazards that may

occur and how are they avoided?
Suggestion: The use of PPE headsets can reduce the
stress on the hearing of the workers.

D. What type of hazards that may

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/components
they are handling
This can be hazardous and also costly
Suggestion: Increase workspace area by
preassembling certain parts outside the main
assembly line

D. What type of hazards that may

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/components
they are handling
This can be hazardous and also costly
Suggestion: Increase workspace area by
preassembling certain parts outside the main
assembly line.

D. What type of hazards that may

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.

E: COST OF PRACTICING OSH IN

FACILITIES AND COMPARE WITH
DOWNTIME COST
PRESENTER MUHAMAD HAZIQ

Facilities Costs
Accidential Prevention
Cost and Description
Air compressor
Motor: 7.5kw / 10hp
Working Pressure (kg/cm): 12 Bar
(Max. 16 Bar)
Compressor Speed
850 rpm
Tank Capacity: 237 Liter
Compressor Block Physical
Dimension
(L x W x H): 700mm x 460mm x
560mm
Weight: 262 kg
Dimension: 1470mm x 650mm x
1150mm
Price: RM 10,600/unit

Accidential Prevention
Cost and Description
Metal table
Price: RM200/unit

Accidential Prevention
Cost and Description
Gas welding (Oxy-Acetylene)
Cutting torch dimension: 18
Price: RM 1,325/set

Accidential Prevention
Cost and Description
Forklift Truck (Toyota)
Load capacity: 2000 2500 kg
Power: Diesel powered
Price: RM28,000/unit

Planning
costs
Accident Prevention
Hired OSH officer
Planning cost
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

Incident
costs
Incident
Consequence
Estimated cost
Using hand tools
Eye damages, cuts and
gashes, strain
RM 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,
RM 10,000.00
serious long term illness
Blocked fire exits
Difficulties when
incident occur
RM 100,000.00

Comparison between preventive and

Incident identification
Preventive cost
incident
costsIncident 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
Using hand tools
RM 20 000.00
RM 15 000.00
RM 500.00
RM 400.00
Stairs-Frayed Carpet
Slips and trips
RM 2000.00
RM 9000.00
RM 1000.00
RM 500.00
At
doorways

(rain),
spillages
Improperly cleaning chip RM 500.00
RM 200.00

Conclusion
From the industrial visit, we were able to
understand how Occupational Safety and Health is
applied in the company. Other than that, we were
also able to identify the hazards that are involved in
the manufacturing site and also how the company is
able to prevent the hazards from happening.
Overall, the company practices safe working
environment, although there are room for
improvements. In conclusion, this visit provided us
a better understanding on the use of Occupational
Safety and Health in the workplace.