PRESENTATION OF

WORKPLACE
ASSIGNMENT
Hazards at DTY-2 Texturizing Machine
of Recron (M) Sdn.Bhd
INDEKS NO : NS 12224
NAMA : NAGARAJAN A/L PALANYSAMY
 INTRODUCTION
I. Recron Malaysia is the largest integrated polyester and
textile company in Malaysia with manufacturing facilities in
Nilai and Melaka.
II. Its products include polyester polymer, nylon polymer, and
various types of yarn including POY, DTY, FDY (Full Drawn
Yarn), HTY (High Twist Yarn) as well as PET (Polyethylene
Terephthlate) bottle grade resins. Over 90 percent of the
companys products are exported worldwide throughout
Asia, Europe, Middle East and the United States.
 INTRODUCTION
1) The usual job for workers at Texturizing machine area
is to push yarn trolleys from warehouse to machine.
 INTRODUCTION
2) Climb on the mobile ladder to install the POY yarn
bobbin
 INTRODUCTION
The main tasks carried out at the Texturizing Machine
areas are:

I. To push yarn trolleys from warehouse to

machine.
II. To Climb on the mobile ladder to install the POY
yarn bobbin
 OBJECTIVES

I. To identify hazards at Texturizing Machine area.

II. To assess various risks induced by any unsafe condition and
unsafe act at the this area which can cause harm to worker
and damage properties.
III. To prioritize the risks according of their risk ratings to
systematically reduce them by effective control measures.
IV. To recommend control measures to counteract the hazards,
preventatively and correctively.
V. To provide a safe working environment to the workers or
anyone working at Texturizing Machine area.
 RISK ASSESMENT METHOD

To determine the risk of the workplace :

1. Hazard Identification
2. Risk Assessment
 HAZARD IDENTIFICATION

The method used to identify safety and health hazards in the

take up area are:
1. Workplace inspection
2. Document review
3. Interview
4. Job hazard analysis
JOB HAZARD
ANALYSIS
No
Hazard Identification Risk Control
Risk assesment
Activities / Action and
Hazard Effect Current Risk Control L S RR
Process Recommendation

Damaged wheel Isolation of trolleys with Schedule cleaning of

bearings due to damaged of wheels and trolley wheels and
1 Physical injury due send to workshop for 4 2 8
yarn waste. replace of damaged
unable to control loaded repair.
(Safety Hazard) wheels.
trolley.

Pushing
Damaged Floor( Trolley handling training.
yarn Trolley path installed
holes on the Falling of trolley and To patch holes on the
trolleys 3 2 6 with metal plate on
2 floor) cause physical injury. floor.
from the floor.
(Safety Hazard) Warning signboards.
warehouse
to
Texturizing
machine Unbalance Trolley handling training.
arrangement of Supervision
area. Falling of trolley and Standard Operation
3 bobbin on the 3 2 6 5 minute toolbox
trolley) (Safety cause physical injury. Procedure and Safe
Do and Dont Posters
Hazard) Work procedure

Trolley handling training. Supervision

Pushing trolley Hitting another operator Standard Operation Counseling
4 too fast. who pushing trolley and Procedure and Safe 4 2 8 Disciplinary action
(Safety Hazard) cause physical injury. Work procedure Refreshment Training
Warning Sign Boards 5 minute toolbox
No
Hazard Identification Risk Control
Risk assesment
Activities / Action and
Process Hazard Effect Current Risk Control L S RR Recommendation

Lifting
Unsafe Mobile Falling from mobile Standard Operation Design new mobile
heavy Ladder ladder with heavy Procedure and Safe 3 3 9 ladder with safety
5
(22KG) (Safety Hazard) load.(22Kg) Work procedure features.
yarn
bobbin
and climb Noise Exposure
on the Monitoring
mobile Audiometry Test Recommended
6 ladder (6 High Noise area Signboards Hearing Protection
Hearing Impairment 2 3 6
(Health Hazard) Hearing protection devices with higher
Feet
devices NRR (33dB)
height) (NRR 29 dB)
and hang
the
bobbin on Bobbin not
installed Standard Operation
to the Bobbin fall on the Bobbin stopper with
properly on the Procedure 2 3 6
7 operator. lock.
winder machine.
machine (Safety Hazard)

holder.
Lifting heavy
Job Rotation
load repeatedly
Cross Training Motorize Bobbin
and climb Joint and muscle pain 3 3 9
8 Standard Operation Lifter
ladder.
Procedure
(Health Hazard)
 RISK ASSESSMENT
LIKELIHOOD DETAILS RATING
The most likely result of the hazard / event being realized 5
Most likely
(daily/weekly)

Has a good chance of occurring and is not unusual 4

Possible
(monthly)

Conceivable
Might be occur at sometimes in future (yearly) 3

Has not been known to occur after many years 2

Remote
(2-10 years)

Is practically impossible and has never occurred (10 years 1

Inconceivable
and above)
 RISK ASSESSMENT
SEVERITY DETAILS RATING
Numerous fatalities, irrecoverable property damage and 5
Catastrophic
productivity

Approximately one single fatality major property damage 4

Fatal if hazard is realized

3
Serious Non-fatal injury, permanent disability

Disabling but not permanent injury 2

Minor

Minor abrasions, bruises, cuts, first aid type injury 1

Negligible
 RISK MAGNITUDE FORMULA

SEVERITY

LIKELIHOOD
1 2 3 4 5

5 5 10 15 20 25
4 4 8 12 16 20
3 3 6 9 12 15
2 2 4 6 8 10
1 1 2 3 4 5
 RISK MAGNITUDE FORMULA
RISK DESCRIPTION ACTION

15 25 HIGH A HIGH risk requires immediate action to control the hazard as

detailed in the hierarchy of control. Actions taken must be
documented on the risk assessment form including date for
completion.

5 12 MEDIUM A MEDIUM risk requires a planned approach to controlling the

hazard and applies temporary measure if required. Actions taken
must be documented on the risk assessment form including date
for completion.

14 LOW A risk identified as LOW may be considered as acceptable and

further reduction may not be necessary. However, if the risk can
be resolved quickly and efficiently, control measures should be
implemented and recorded.
 MOST CRITICAL
SAFETY AND HEALTH
HAZARD
 HAZARD IDENTIFICATION RISK ANALYSIS

NO. ACTIVITY HAZARD L S R

Unsafe Mobile Ladder

(Safety Hazard)
3 3 9
High Noise area
(Health Hazard)
2 3 6
Lifting heavy (22KG) yarn
bobbin and climb on the Bobbin not installed
mobile ladder (6 feet properly on the
1
height) and hang the machine. 2 2 4
bobbin on to the winder (Safety Hazard)
machine holder. Lifting heavy load
repeatedly and climb
ladder. 3 3 9
(Health Hazard)
 CONTROL MEASURE RECOMMENDATIONS
For the most critical safety hazard identified at take up area, which is
UNSAFE MOBILE LADDER.

Elimination
Removing Mobile Ladder from texturizing machine area is not possible and it is very costly.
Substitution
Substitution of the mobile ladder is not necessary and it is very costly.
Isolation
Isolating the operators from the hazards of using the mobile ladder is not feasible too.
Engineering Controls
The Mobile Trolley redesigned with improved safety features.
Administrative Controls
The Safe work procedure can be revised. Every trolley distance need to be more than 3 meters from
each other.
Appoint a traffic controller to control the passage of trolley. The traffic controller also responsible to
give warnings to other worker of incoming trolley.

Personal Protective Equipment

Wear impact resistant gloves when pushing trolley.
 IMPROVEMENTS
TOP RAIL

HAND
RAIL

WIDER
STEPS
BRAKE
AFTER BEFORE
 IMPROVEMENT

BEFORE AFTER
 IMPROVEMENT

BEFORE AFTER
 CONTROL MEASURE RECOMMENDATIONS
For the most critical health hazard identified at Texturizing Machine Area, the
repetitive movement of worker to carry the bobbin and climb
on the mobile ladder.
Elimination
The mobile ladder climbing job cannot be eliminated as the machine designed is
such.

Substitution
Substitution of the mobile ladder is very costly.
Isolation
solating the operators from the hazards is not feasible as that is the main activity
I

of the process.

Engineering Control
Engineering control is very costly.
Administrative Controls
Implement Job Rotation System. (cross training, Safe work procedure,
5Minutes Tool Box meetings)

Personal Protective Equipment (PPE)

No recommended PPE.
REVIEW PROGRAMME OF THE PROPOSED
CONTROL MEASURE
Health Hazard
To conduct Body Part symptoms survey once for every six months. If
the results show that worker no longer have pain or muscle sprain, we can
conclude the recommend control measure is effective.
To create a feedback form. If worker still feel pain, they can give
feedback by filling the feedback form. So, we can analyze the percentage
of workers who still having pain after the proposed control measure. The
higher the percentage indicates that the proposed control measure is not
effective.
To collect and analyze data of medical leave before and after
proposed control measure is done. The higher the percentage of worker
getting medical leave indicates that proposed control measure is not
effective.
REVIEW PROGRAMME OF THE PROPOSED
CONTROL MEASURE
Safety Hazard
Conduct inspection periodically. Observe how the workers do
the task after proposed control measure is done. Record new
findings (if any).
Review document such as accident and near miss reports at
the take up area from time to time. If the statistics reduce, that
means recommend control measure is effective.
Do some Q&A session to get the feedback from worker
regarding effectiveness of the proposed control measure. Besides
that, we can get information from the worker of new hazard which
may arise.
 Benefit of Control Measure
Recommendation
I. The accident cases will be minimized thus
reducing the cost of accident. (Cost of training
new worker, Cost of overtime work, cost of
accident investigation). The company can
utilize the cost for other purpose.
II. Morale of worker increase. This is because they
feel that management cares about their safety,
health and welfare. When morale of worker
increase, productivity will increase which
contribute to companys profit.
THE END
THANK YOU