10 minutes presentation on Workplace Assignment in Production Packing Line of Indirect Heat X (ID-X) Section of Company Industrial Minerals Sdn Bhd from January-March 2018.

1. Reports of Hazards
in Production Packing Line of
Indirect Heat X (ID-X) Section of
Company Industrial Minerals Sdn Bhd
(Pseudonym)

2. • SKK Chemical Audit 08021820180208_161941.mp4

3. IDX Operator
Shift : Day Shift
Name : XXXXXXX
Age : 32 years old
Gender : Male
Origin : Bangladesh
Height : 167cm
Weight : 55kg
Medical History : NIL
Working Hours : 8am – 8pm
Year Start Work : 2017
Shift : Night Shift
Name : YYYYYYYYY
Age : 25 years old
Gender : Male
Origin : Nepal
Height : 160cm
Weight : 51kg
Medical History : NIL
Working Hours : 8pm – 8am
Year Start Work : 2016
Salary Incentive base. According to tonnage produced.

4. Slide 18

5. General Objectives
• Occupational Safety and Health Act
1994, Act 514 (OSHA 1994), Part IV,
General Duties of employers and self-
employed person - Regulation 15 (1)
and Regulation 15 (2)
• Occupational Safety and Health
(Safety and Health Officer)
Regulations, Part V, Duties of Safety
and Health Officers - Regulation 18
(a), Regulation 18 (b) and Regulation
18 (f)
Specific Objectives
• To identify the safety and health hazards that
may cause harm to employees at IDX
• To evaluate the chances of safety and health
risk for identified hazards as per Risk
Assessment technique (qualitative and semi-
quantitative analysis)
• To evaluate the adequacy of existing control
measures
• To propose further rational control,
preventive and corrective measures
appropriate for the company to prevent or
reduce risk and exposure
• To enable employers to plan, introduce and
monitor preventive measures to ensure that
the risks are adequately controlled at all times

6. • “Guidelines for Hazard Identification, Risk
Assessment and Risk Control (HIRARC),
Year 2008” by the Department of
Occupational Safety and Health Malaysia,
JKKP DP 127/789/4-47, ISBN 978-983-
2014-62-1
• Qualitative & Semi Quantitative Method
• Focused on only two groups of hazards -
Health Hazards & Safety Hazards
Note:
JKKP - Jabatan Keselamatan dan Kesihatan Pekerjaan Malaysia, a
Department under the Ministry of Human Resources
ISBN - International Standard Book Number is a unique numeric
commercial book identifier
Risk Assessment Method

7. Hazard in focus
Safety
Hazard
A force strong
enough to cause
injury, or damage
to property
Obvious Injury
Slip/ trip hazards,
Pressure systems, Vehicles
Lifting/ manual handling,
Fire hazards, Working Alone,
Moving parts - machinery, tools &
equipment
Work at height, Ejection of material,
Cause harms
when workplace
controls are not
adequate
Health
Hazard
Any agent that
can cause illness
to an individual
May produce
acute effects or
chronic problems
Chemicals
Biological hazards
Physical agents
Work design (ergonomics)
hazards
Symptoms may
not be recognized
immediately

8. Hazard Identification
Technique
•Interview with Worker
Workplace
Assessment
•Workplace Audit Inspection
Workplace
Inspection
•Job Safety Analysis
Hazard
Analysis

9. The Formula for Risk is:
• L = Likelihood
• S = Severity
Risk Matrix Used
L x S = Relative Risk,
SEVERITY (S)
1 2 3 4 5
LIKELIHOOD(L)
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
High Medium Low
RR = 15-25 (HIGH)
• 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.
RR = 1 – 4 (LOW)
• 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.
RR = 5-12 (MEDIUM)
• Requires a planned approach to control the hazard and
applies temporary measures if required.
• Actions taken must be documented on the risk assessment
form including date of completion.

10. Risk Matrix Used
1. Likelihood
of an
occurrence
2. Severity of
Hazard
LIKELIHOOD (L) EXAMPLE RATING
Most Likely The most likely result of the hazard/ event being realized 5
Possible Has a good chance of occurring and is not unusual 4
Conceivable Might occur at some time in future 3
Remote Has not been known to occur after many years 2
Inconceivable Is practically impossible and has never occurred 1
Table A: Likelihood
SEVERITY (S) EXAMPLE RATING
Catastrophic
Numerous fatalities, irrecoverable property damage and
productivity
5
Fatal
Approximately one single fatality major property damage
if hazard is realized
4
Serious Non-fatal injury, permanent disability 3
Minor Disabling but not permanent injury 2
Negligible Minor abrasions, bruises, cuts, first aid type injury 1
Table B: Severity

11. List of Hazards Identified
Safety Hazard
1. Forklift Overturn
(RR=12)
2. Trip and Fall (RR=8)
3. Slip and Fall (RR=6)
4. Manual Handling &
Repetitive Movement
(RR=4)
Health Hazard
1. Kaolin Mineral Dust
(RR=15)
2. Noise (RR=15)
3. Ergonomic (RR=9)
4. Heat Stress (RR=8)

12. Safety Hazards

13. Work Activity:
Forklift Operations, Maneuvering &
Transportation of finished goods
into warehouse
Description:
Forklift overturns due to uneven
surfaces (potholes/ cracks) and
unsecured and unstable Load
1. Operator Slip and Fall out from
Forklift Truck onto the ground.
2. Worker body parts (Feet, arm,
head) may be crushed and
broken by Forklifts when it
overturns to the side.
3. Worker may also suffer from
bruises or scratches on body
parts.
(1) Findings: Safety Hazards
Classification: Vehicle Mechanical Hazard
• Fatality/ Serious Body Injury due to Forklift Truck
Overturn and hit worker

14. Forklift Truck Overturn
Risk Rating – 12
Likelihood Severity Risk Rating
3 4 12
Conceivable
• Might
occur at
some time
in future
Fatal
• 1 single
fatality
• Major
Property
Damage
Medium (5-12)
• Requires a planned
approach to control
hazard
• To apply temporary
measures if
required.
• Actions taken must
be documented on
the risk assessment
form including date
of completion.

15. Severity Rating – 4
Current Control Measures
• PPE enforcement
• Administrative Controls
• Driver is not competent
Consequence/ Impact of Hazard
• Cause Fatality or Permanent Injury
• Operator Slip and Fall out from
Forklift Truck onto the ground
• Operator body parts (Feet, arm,
head) may be crushed and broken
by Forklifts when it overturns to the
side
• Worker may also suffer from
bruises or scratches on body parts.
i. Department of Safety and Health
Malaysia, Fatal Accident Case Report
(07 May 2018)
- caused by overturned forklift (2014 - 2017)
- At least 1 fatality/ year was recorded
- Deceased/ victims suffered from serious
injuries, severe bleeding to the head,
internal body injuries, injuries to the neck
and back and broken hip-bone.
- The victims were pinned, struck or crushed
by the overturned forklift
- Recorded observations shows that the
victims did not undergo forklift driving and
handling training
- is not qualified to operate the forklift
- no safe work procedure in organization
- poor work environment due to
uncontrolled weather condition
DOSH Fatal Accident Case
Date Title Case Location Summary Case
Contributing
Factors
Observation
10-02-
2017
Died being
pinned by
forklift
Factory,
Sarawak
An overturned forklift hit the
driver due to failed making a U-
turn
Serious injuries to
the head
1) forklift was not in
proper condition to be
used
2) Victim did not undergo
forklift driving training
14-05-
2016
Died being
struck by
forklift
Port, Johor
Prior to the incident, the victim
was driving the forklift out of
the truck. Suddenly, the rear tyre
slip off the ramp lead the forklift
to overturned. He jumped off
but unfortunately forklift fell on
him. He died at the hospital
Internal injuries
17-12-
2015
Died being
struck by
forklift
Quarry sites,
Sabah
The accident occurred as the
victim driving forklift down the
hill. The vehicle suddenly out of
control causing it to overturned.
The victim was pinned under the
forklift
serious injuries to
the neck and back
Slippery road conditions
30-01-
2015
Died by
forklift
accident
Material
Storage,
Pulau
Pinang
Prior to the incident, alleged
victim was driving a forklift. No
witnesses at the scene. Victim
was found lying on the ground
with the forklift overturned
Bleeding in the
head
09-09-
2014
Died being
crushed by
forklift
Construction
site, Pulau
Pinang
The unbalanced forklift driven
by the victim has caused it to
overturned and crush the victim
Severe bleeding in
the head
26-06-
2014
Died being
pinned by
forklift
Rice
Milling,
Perak
Forklift overturned and crash the
driver while carrying work of
lifting and placing jumbo bag
Broken hip bone
-No safe work procedure -
Victim has never
undergone intensive
training regarding to
forklift handling
22-05-
2014
Died crushed
by forklift
Factory,
Kuala
Lumpur
Forklift overturned and fell on
top of the victim.
Serious injuries to
the head
Victim is not qualified to
operate the forklift
OSH INFO
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Last Modified: 07 May 2018
Hazard is Fatal if the gravest form of injuries is being realized. Approximately 1 single fatality expected from it.
i. Department of Safety and Health
Malaysia, Fatal Accident Case Report At
least 1 fatality was recorded yearly
ii. Factories and Machinery (Person-In-
Charge) Regulations, Schedule, Regulation
20
• revised in 2014 to include Material Handling
Equipment including forklift, conveyor,
stacker, excavator, tractor, dumper or
bulldozer.
• Forklift does not require Certificate of
Registration with the Department of Safety
and Health, Malaysia.
• DOSH requires employer to do Safe Work
System for safe handling of forklift
• Employer to provide adequate training and
supervision to operators
iii. OSHA Act, Part IV (General Duties of
Employers and Self-employed Persons),
Regulation 15 (1) and (2) to ensure that
workplace is safe for employees to
perform their duties.

16. Likelihood Rating – 3
Exposure Duration: 11 hours
Days: Monday - Saturday
Salary:
Incentive base according to
tonnage of product produced
Average Daily Production:
9MT/ shift (9 pallets)
Distance to Warehouse :
500m
PPE used:
• Safety Helmet (not strapped)
• Seat Belt not strapped
• Safety Boots is in good condition.
Administrative Controls:
• Night Shift Worker attended training for
"CAT Lift Truck Operator Safety Training"
on 03/01/18 provided by CAT Lift Trucks -
Tractors Material Handling
• Day Shift Worker was absent from formal
training.
• WhatsApp Chatgroup to monitor Forklift
condition and to report any damages,
breakdowns and misused. PIC has been
appointed. Manager - Jean Ng, Co-
ordinator – Gnana
• Penalty is implemented by HR to
Operators who fail to follow rules (salary
deduction)
• Scheduled Maintenance done daily and
periodically by operator and supplier
• CAT Supplier is proactive in supporting
repair & maintenance at site
Conceivable – Might occur at some time in future
Existing Risk Control
Management is taking serious
notice of forklift truck due to
high maintenance and repair
cost.
Relies heavily on
Administrative Control and
implementation of PPE for all
employees
No major first aid/ casualties
reported.

17. Control Existing Risk
Control
Proposed Risk Control
Elimination NIL Preventive Control:
 Elimination of the use of Forklift Truck
Corrective Control:
 Repair all uneven surfaces, cracks & potholes on forklift
pathways.
Substitution NIL Preventive Control:
 Substitution on worker with robots
 Use Robotic Arms and Automation Packing to transfer bags to
pallet and warehouse instead of using Forklift truck
Engineering
Control
NIL Preventive Control:
 Substitution of traditional concrete flooring to Industrial Epoxy
Flooring
 Redesign job and processes to make it safer. No mobile
transportation needed from packing area to warehouse store.
Transportation can be done using conveyor belt system
directly from packing area to warehouse store.
 use machine automation which can straight away compact,
strap, shrink-wrap and storage of finished goods in warehouse
after packing completed.

18. Administrative
Control
i. PPE Inspection
ii. Training on Forklift Handling
iii. Maintenance and repair
contract with multiple Forklift
Truck suppliers. The
management has engaged
new suppliers who are
proactive in supporting the
reduction of down time due
to forklift damages or
failures. The suppliers are
XXX (Hire-purchased) and
XXX Lift Trucks (Rental)
iv. WhatsApp Group Chat -
Proactive report on Forklift
condition
v. WhatsApp Group Chat - KM
OSHE Committee OSHE
Proactive Incidents and
delinquents report and
notification.
vi. Penalty impose by HR
Corrective Control:-
 Review current “Vehicle Operation Safety
Procedure” together with workers and implement
it. Use Job Safety Analysis Techniques.
 Patch existing potholes and cracks and smoothen
and lowered uneven surfaces.
Preventive Control:-
 Create training schedule include new workers.
 Provide refresher training for old workers
 Workplace Audit by OSHE Committee to ensure
workplace is floor is free from potholes, cracks and
uneven surfaces
 Periodic maintenance on floor to cover or repair
potholes, cracks and uneven surfaces at work area
 Create clear lines and a safe boundaries between
pedestrian and driving pathways.
 Warning signage on speed limit especially at turning
points
 Install speed bumps before dangerous turnings
 Follow load limit of mobile equipment set by
supplier. Refer Operation Manual for guidelines.
 Travel on inclines forward with load uphill. Travel

19. Personal
Protective
Equipment
i. Safety Helmet - Brand: XXXX,
Model: HG1-PHSL, Description:
ABS Shell with Slide Lock System,
chinstrap and sweatbands.
Provided by company at Admin
Office upon commencement of
contract.
ii. Safety Boots - Company provided
monthly allowance of RMXX to
operator to purchase own safety
boots. No specific requirements
implemented for Safety Boots.
Corrective Control:
 Safety Helmet must be strapped and in
good condition
 Operator to use seatbelt when driving
forklift
Preventive Control:
 To provide guidelines of Safety Boots
functional characteristic requirements.
 To provide recommendations of approved
Safety Boots brand and model and
approved supplier contacts
 To provide training on care of PPE
 To provide awareness training on function
of PPE

20. • Slide 27

21. Work Activity:
Filling in kaolin powder into 25kg paper bag
Description:
Walking Path is not free from obstructions
of accumulated powders, forming small
hills. Proper Housekeeping cannot be done
due to too many powder leakages from
machines. Floors are also not free of boxes,
swarfs, off-cuts & other trip hazards,
hidden by powder wastages.
No designated walking and driving path and
no designated area to place pallets and do
compacting and blowing of end product
available as lines cannot be drawn on the
floor.
(2) Findings: Safety Hazards
Classification: Work Environment Hazard (Trip & Fall)
– Can cause Disabling (but not permanent injury) to worker
due to Powder Leakage & Wastage Accumulation on ground

22. Trip & Fall - Accumulated powder on Floor,
Risk Ratings – 8
Likelihood Severity Risk Rating
4 2 8
Possible
• Has a good
chance of
occurring
• is not
unusual
Minor
• Disabling (but
not
permanent
injury)
Medium (5-12)
• Requires a planned
approach to control
hazard
• To apply temporary
measures if
required.
• Actions taken must
be documented on
the risk assessment
form including date
of completion.

23. Work Activity:
Operator walks about to manage the
operation of IDX Machineries &
preparation of Product Packing (25KG
Paper Bags) at Packing Area
Description:
Slip, Trip and Fall due to slippery floor
surfaces especially during rainy
season or when there is liquid spillage
on floor. Accumulated powder on
floor will make mud formation easily
formed. Mud will also clump to safety
boot's sole.
(3) Findings: Safety Hazards
Classification: Work Environment Hazard (Slip & Fall)
• Can cause Disabling (but not permanent injury) to worker
due to Muddy Ground

24. Slip & Fall – Muddy Ground
Risk Ratings – 6
Likelihood Severity Risk Rating
3 2 6
Conceivable
• Might occur
at some
time in
future
Minor
• Disabling (but
not
permanent
injury)
Medium (5-12)
• Requires a planned
approach to control
hazard
• To apply temporary
measures if
required.
• Actions taken must
be documented on
the risk assessment
form including date
of completion.

25. Work Activity:
Arranging of bags on pallets
Description:
Repetitive contact with rough wood
surfaces (pallets) and paper fibre (paper
bags) when doing bag arrangements on
pallets, blowing of powders from bags &
wrapping of load.
(4) Findings: Safety Hazards
Classification: Manual Handling - Lifting, Carrying,
• Can cause Minor abrasions, bruises, cuts, first aid type injury to
worker due to Repetitive Movements contact with Packing Materials

26. Lifting, Carrying, Repetitive Movements
of Packaging Material
Risk Ratings – 4
Likelihood Severity Risk Rating
4 1 4
Possible
• Might
occur at
some time
in future
Negligible
• Minor
abrasions,
bruises, cuts,
first aid type
injury
Low (1-4)
• Acceptable & further
reduction may not be
necessary.
• If risk can be resolved
quickly & efficiently,
control measures
should be
implemented &
recorded

27. • Slide 38

28. Health Hazards

29. Work Activity:
Filling in kaolin powder into 25kg paper bag
& dusty workplace environment
Description:
Paper Bag is swollen due to the air filling the
bag. The air will push the access powder out
from the bag when it reaches 25kg weight,
causing powder spillage to occur. The dust
particulate from the spillage will be released
to environment. Operator inhale the kaolin
dust particulate.
Other dust particulate sources released to
same work environment are leakages from
Vibrating Screen, Separator and Reject
powder valve
(1) Findings: Health Hazards
Classification: Chemical – Chronic Toxicity through
Kaolin Mineral Dust Inhalation exceeding the PEL set by
regulatory bodies

30. Source of dust

31. Inhaled kaolin appears as small golden brown
particles and usually results in pulmonary
fibrosis. In this image kaolin is present within
alveoli and fibrosis is absent.
Inhaled kaolin appears as small golden brown
particles and usually results in pulmonary fibrosis.
This image depicts a fibrotic nodule containing tiny
golden brown particles of kaolin.
https://commons.wikimedia.org/wiki/File:Kaolinosis_3.jpghttps://commons.wikimedia.org/wiki/File:Kaolinosis_1.jpg
Severity of disease

32. Kaolin Mineral Dust Inhalation
Risk Rating – 15
Likelihood Severity Risk Rating
5 3 15
Most Likely
• The most
likely
result of
the hazard
being
realized
Serious
• Non-fatal
• Cause
permanent
disability
High (15-25)
• 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.

33. Critical Health Hazard – Kaolin Dust
Severity = 3
Hazard is Serious as it can cause non-fatal injury and permanent disability.
DOSH Statistics “Occupational Disease & Poisoning by Type of
Disease, 2016” - Highest number of injury
1. Occupational Noise-related Hearing Disorders (2876
cases)
2. Occupational Muscular-Skeletal Disorders (173 cases)
3. Occupational Lung Diseases (98 cases)
ii. Occupational Safety and Health (Use and Standards of
Exposure of Chemicals Hazardous to Health) Regulations
of the OSHA 1994 and Regulations, Schedule I. Kaolin
mineral (CAS No. 1332-58-7) – Allowable PEL (8 hour
Time-weighted average) airborne concentration:-
• particulate matter containing no asbestos , < 2mg/ m3
• crystalline silica (respirable fraction), <1%
i. WHO Geneva, 2005 published Report Summary of
“Evaluation of Kaolin on human health risks and effects
on the environment” conclude that:
a) Long-term exposure to kaolin - benign pneumoconiosis
(kaolinosis). Deterioration of lung function has been
observed only in cases with prominent radiological
alterations
b) Kaolin that contains quartz, which is known to cause
silicosis and lung cancer
c) The biological effects of clay minerals are influenced by
their mineral composition and particle size. The
decreasing rank order of the potencies of quartz,
kaolinite, and montmorillonite to produce lung damage is
consistent with their known relative active surface areas
and surface chemistry.
iii. Factories and Machinery (Mineral Dust) Regulations
1989, Schedule. Mineral Dust PEL :
• Respirable Dust (free silica <1% in weight) < 5mg/m3
• Total dust averaged over an eight-hour period < 10mg/m3
• Crystalline silica (Respirable Quartz) < 0.1mg/m3

34. Critical Health Hazard – Kaolin Dust
Likelihood = 5
Hazard is Most Likely to occur
The mineral is found in abundance in all work areas. Other
than the processing and refinement of kaolin clay, the most
important final steps of kaolin production is centralized at the
production line, thus making it a critical work hazard which is
impossible to avoid.
i. Nature of Company Business and Operations. Duration
of exposure to kaolin dust particulate for the each shift
operator is maximum 11 hours daily. HR design the
operator’s salary as Incentive base.
Average= 9 MT/ shift, subjecting each operator to
manually handle an average of 360 bags of kaolin
powder daily. The dust particulate spillages will be
released to Operator’s breathing zone. Other dust
particulate sources - Vibrating Screen, KM Separator
and Reject Powder Machines at IDX.
ii. Previous Monitoring Report by Competent Person
a) Chemical Exposure Monitoring - 08 – 09/10/2014.
Personal Exposure Monitoring result - contaminant
concentration of Inhalable Particulate, Respirable
Particulate and Crystalline Silica (Quartz) in IDX are within
their respective PEL – 8hrs TWA Exposure Limit as per
OSH (Schedule I of USECHH) Regulation 2000 and Factory
& Machinery (Mineral Dust) Regulation, 1989.
b) Dust Exposure Monitoring - 26 June 2004.
Results of the personal exposure - high risk dusty areas
in the plant, which is Production Area, the personal dust
exposure monitoring has confirmed that “packer” are
exposed to dust level exceeding the stipulated
permissible Exposure Limit (PEL) of 2mg/m3 of
respirable dust averaged over an 8 hour period.
Conclusion of the report indicated that there is no
Respirable Quartz detected in the Respirable Dust
sampled.
iii. Existing Risk Control
• CHRA, 17/12/2014, Operator is wearing PPE, N95 Mask as
per advised by (Safetyware 3223 (without valve)).
Operator does not devotedly use the mask provided due

35. Control Existing Risk Control Proposed Risk Control
Elimination NIL NIL
Substitution NIL Preventive Control:
i. Substitution of packing operator with robotic hands
Engineering
Control
i. Work area is naturally ventilated Preventive Control:
i. Isolation of machinery from worker – air conditioned
room with local exhaust ventilation at source of
hazard (valve packing machine)
ii. containment of dust using dust by installing bag
filter system, scrubber system and local exhaust
ventilation to ensure dust does not escape to worker
breathing zone and to workplace environment
iii. Wall barrier to segregate packing area and machines
to isolate worker from dust exposure
iv. To redesign the work area using automization
bagging system and robots
Corrective Control:
i. To cover all leakages at machines emitting out dust

36. Administrative
Control
i. Workers are not allowed
eating, drinking & smoking
inside work area.
Preventive Control:
i. Conduct Medical Surveillance on worker
ii. Create warning signage of side effects of kaolin dust to health
and list down the compulsory PPE to use when handling mineral
iii. Make SDS available at work area for workers to read.
iv. To conduct schedule Chemical Exposure Monitoring by
competent person
v. Emergency Evacuation Plan & First Aid when release of dust
vi. Posters at work area to remind worker of hazard exposure
vii. Warning signage at work area as reminder of required PPE
viii. Provide training on product hazard and refresher training
ix. First Aid measures to treat hazard if worker is over exposed
Corrective Control:
• Impose penalty on workers who do use PPE
Personal
Protective
Equipment
i. N95 mask model: XXXX 3223
(without valve). Provided by
company upon request at
Admin Office.
i. Provide N95mask Model XXXX 3223 (with Valve) for more
comfort. Mask must be disposed when not functioning.
ii. Provide half-face silicon Respirator fitted with filter cartridge
(reusable, better hygiene and cost saving) Current mask is Not
adequate. Work area is too dusty and require frequent change of
mask to ensure efficiency
iii. Wear safety goggles/ face shield when handling chemical to avoid
chemical splash into eye. Currently no protection worn to
protect skin & eyes from chemical exposure.
iv. Training on how to clean & maintain mask
v. Awareness training on function of mask

37. • Slide 43

38. Work Activity:
Overall packing and handling operation
at IDX
Description:
Source of Noise comes from machineries
in that work area, Forklift and Cleaning
Equipment. Overall there are 22
equipment working concurrently in IDX.
Worker is unable to hear someone
talking in a normal voice or sound of
anyone approaching at 2 metres away
when machineries are in operation.
Slide 5
Findings: Health Hazards
• Classification: Energy (Noise) – Continuous daily exposure
exceeding the PEL that can cause Non-fatal Cause permanent
disability to worker

39. Noise – Continuous daily exposure,
Risk Ratings – 15
Likelihood Severity Risk Rating
5 3 15
Most Likely
• The most
likely result
of the
hazard
being
realized
Serious
• Non-fatal
• Cause
permanent
disability
High (15-25)
• 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.

40. Work Activity:
Weight check and arrangement of bags on
wooden pallets
Description:
1. In 1 day, operator packed average of
9MT/ Shift = 360 bags daily.
2. Operator bend to pull the bag mouth
out from the valve.
3. Lift and carry the filled 25KG PB with 2
hands to his left onto the weighing
machine for weight check.
4. Lift, carry and swing or heave the bag
onto the pallet by twisting his mid-body
anticlockwise.
5. Awkward postures for the
arrangements of bags at base of pallet
and above worker's shoulder.
Findings: Health Hazards
Classification: Manual Handling - Ergonomic, Lifting, carrying
and Repetitive Movements that can cause serious Non-fatal or
permanent disability to worker
Note: Jumbo bag packing is done around 5x in a month.

41. Manual Handling - Ergonomic, Lifting,
carrying and Repetitive Movements,
Risk Ratings – 9 Likelihood Severity Risk Rating
3 3 9
Conceivable
• Might occur
at some
time in
future
Serious
• Non-fatal
• Cause
permanent
disability
Medium (5-12)
• Requires a planned
approach to control
hazard
• To apply temporary
measures if
required.
• Actions taken must
be documented on
the risk assessment
form including date
of completion

42. Work Activity:
Operator checks temperature at Rotary
Dryer daily to ensure temperature of dryer
is consistently XX˚C.
Description:
• Contact with extreme heat from Rotary
Dryer. Temperature of dryer is set at
XX°C.
• Overall workplace environment is
Naturally Ventilated.
• No fan provided.
• No control in Work Environment.
Subjected to changes in weather.
• No PPE provided for heat protection
(4) Findings: Health Hazards
Classification: Work Environment (Extreme Temperature) –
Exposure to heat daily – Heat stress that exceed the PEL to
worker and can cause fatality if hazard is realised

43. Heat Stress ,
Risk Ratings – 8
Likelihood Severity Risk Rating
2 4 8
Remote
• Has not
been
known to
occur after
many years
Fatal
• App. 1 single
fatality if
hazard is
realised
Medium (5-12)
• Requires a planned
approach to control
hazard
• To apply temporary
measures if
required.
• Actions taken must
be documented on
the risk assessment
form including date
of completion.

44. Impact of Risk to
Organization
Negative
Public
Perception
Indirect Impact
Negative
Employee
Perception
Direct Impact
damages to employees, environment
and property assets. It can lead to
increase of medical cost or losses in
investment and profit (hidden cost)
Negative
Client
Perception
Indirect Impact
procure prolong liabilities due to damage company
reputations which may lead to loss of procuring
future clientele contract and businesses.

45. Budget Friendly Recommendation
Safety Hazard Health Hazard
Preventive Control: Engineering Control
using Isolation of machinery from worker
by providing air-conditioned room for
packing operator with Local Exhaust
Ventilation at Packing Valve Machine
Corrective Control: Patch existing potholes
and cracks and smoothen and lowered
uneven surface
Corrective Control: Administrative Control
by providing a better N95 mask with valve
or half-face silicon respirator mask fitted
with filter
Preventive Control: substitution of
traditional concrete warehouse flooring to
Industrial Epoxy Flooring

46. Review of Control Measures
Safety and Health Audits
• Periodic Internal Audits can review
the effectiveness of the control measures.
• Formal Audit of the recognized security
management system certification body
needs to be adapted. Examples of security
management systems are OHSAS 18001.
This may be the future management's
consideration.
Accident Reporting
• First Aid Report, NADOOPOD
Report, Medical Leave Report
• Every incident / accident occurring at the
workplace should be recorded. By checking
the crash report, the level of effectiveness of
control measures can be identified. If the
level of effectiveness is low, more effective
control measures needs to be introduced.
Example of report
• Accident reports can be reviewed by the
safety and health committee. The committee
reserves the right to determine whether
additional control measures are required.
When the committee meets (once every 3
months) the discussion of the effectiveness
of the control method can be an agenda.
• Important to ensure its effectiveness
• In accordance with the requirements of this legislation
• Effective management system and no negligence of legal aspects

47. Benefit of Recommended Control Measures
Positive Company
Image & Prominent
in matters to Safety
& Health
Cultivation of
Positive Workplace
Safety Culture
among Employees.
Reduce workplace
accidents & incidents
Employee
productivity & work
quality will improve
Worktime &
workforce fully
utilised to earn
profit
Cost Effective
Reduce or avoid
medical cost and
other hidden costs
When all control measures are taken
comprehensively, workplace accidents
can be prevented. Employees will also be
more careful while working and trying to
avoid accidents. Therefore, the number of
accidents or incidents can be reduced
due to lack or unnecessary
accident at the workplace.
no postponement and
termination of work due to
unemployment in the
workplace.
employees will be
able to work more
comfortably without
worrying about their
safety and health
Less accidents, especially incidents which
causes death & serious injuries. Will increase
client's confidence and trust in company
capability to offer quality service and trump
competitors in the industry.

48. • Slide 21

49. End
Thank you

50. Content
• Introduction of Workplace
• Objective of Report
• Method of Risk Assessment
• Risk Matrix Used
• Findings
• Discussions
• Recommendations

51. Risk Ratings – Safety Hazards
1. Hazard Identification 2. Risk Analysis
Ref.
No.
Hazard
Risk Rating
L S R
1 Classification: Mechanical Hazards – Vehicles – Can
cause Fatality/ Serious Body Injury due to Forklift
Truck Overturn and hit worker
3 4 12
2 Classification: Work Environment - Fall, Trip & Slip –
Can cause Disabling (but not permanent injury) to
worker due to Powder Leakage & Wastage
Accumulation on ground
4 2 8
3 Classification: Work Environment - Fall, Trip & Slip
(Physical Hazard) – Can cause Disabling (but not
permanent injury) to worker due to Muddy Ground
(Kaolin Powder wastage accumulating on floor mix
with rain water)
3 2 6
4 Classification: Manual Handling - Lifting, Carrying,
Repetitive Movements – Can cause Minor abrasions,
bruises, cuts, first aid type injury to worker due to
Repetitive contact with Packing Materials & Mineral
(cause dry hands/ skin, calluses and splinters)
4 1 4

52. Risk Ratings – Health Hazards
1. Hazard Identification 2. Risk Analysis
Ref.
No.
Hazard
Risk Rating
L S R
1 Classification: Chemical – Chronic Toxicity –
Mineral Dust Inhalation exceeding the PEL set by
regulatory bodies
5 3 15
2 Classification: Energy – Noise – from 22
machineries in that work area, Forklift Trucks and
Product Cleaning activities continuous daily
exposure exceeding the PEL that can cause Non-
fatal Cause permanent disability to worker
5 3 15
3 Classification: Manual Handling – Ergonomic -
Lifting, carrying & Repetitive Movements of heavy
weights daily that can cause serious Non-fatal or
permanent disability to worker
3 3 9
4 Classification: Work Environment - Extreme
Temperature (Heat) – Heat stress – that exceed
the PEL to worker and can cause fatality if hazard
is realised
2 4 8

53. • Employee
(Forklift Overturn)
– Fatality
- Permanent disability (Vision,
Hearing, Speech Loss)
- Temporary disability (Recovery)
- Physical Injury (Fractured
bones)
- Psychological Trauma (Phobia,
Mental Stress, Emotional
Stress)
• Employee
(Mineral Dust Exposure)
- Permanent impairment
- Occupational Asthma
caused by particulate
irritants (Radiological
Pneumoconiosis - Kaolinosis
& fibrosis)
- Massive fibrosis which can
lead to disablement
- Confluent lesions in
respiratory tract
- Psychological Trauma
(Phobia, Mental Stress,
Emotional Stress
Safety & Health Hazard
Direct Impact
• Employer
- Cost Incurred for Medical
& Hospitalization
• Assets
- Cost to repair damage
property
- Replacement of product
- repair/ replacement of
Forklift
Insured Costs – covering injury, ill health & damages

54. Indirect Impact
• Employee
- Lost capability to perform
in full physical capacity
• Employee’s family
- Emotional Stress. Will
push for explanation as
soon as possible
- Lost of source of income
• Colleague
- Motivation decreased
- Decrease in salary due to
halt in production
- Additional workload due
to loss of manpower
- Psychologically disturbed:
Trauma,
- Emotional & Mental stress
Safety & Health Hazard
• Environment
- oil contamination on ground,
release of powders to ground &
air
- Fined by DOE
- Incurred cost to clean
environment
• Reputation
- Bad press review. Famous for the
wrong reason
- May affect existing customer
reputation. May terminate future
contract
- Lost of other new contact as
most big clientele require
compliance to OSHA
Hidden & Uninsured (8x – 36x more costly)
• Employer - Cost Incurred for:-
- Loss time injury
- Send back worker to hometown
- acquiring replacement worker
- Higher insurance cost
- Fine or Compound by regulated
bodies - DOSH, Labour Law,
PERKESO
- Legal cost
- Overtime Payment to
replacement worker
- Site clearing expenditure
- Production Delay
- Compensation costs to worker
- If fatality occur, production
stopped for police investigation
- Unable to secure fair price for
product to generate higher profit
income