ABSTRACT

This research is basically about to plan for facilities compliance OSHA's Ergonomic

regulation in the manufactwing industry. This report contains of five chapters;

introduction, literature review, methodology, data collection and data analysis. This

research is based on the OSHA need's and fiom the law which been approve in 1994.

In methodology, this research is done by evaluating three aspects which are indoor

air quality, sound level and illumination. The equipments that will be used are sound

level and light meter and indoor air quality monitor. In data collection, comparison

will be made between data and standard data for all fields. Besides that, some

suggestions also have been given to solve all disadvantages in each line.

ABSTRAK

Secara asasnya, kajian ini adalah mengenai perancangan perlaksanaan peraturan-

peraturan ergonomik dalam Akta Kesihatan dan Keselamatan Pekerjaan (OSHA)

dalam industri pembuatan. Laporan ini mengandungi lima bab penting iaitu

pengenalan, kajian ilmiah, kaedah, pengumpulan data dan penganalisisan data.

Kajian ini berdasarkan keperluan yang dikehendaki OSHA yang dikuatkuasakan

pada 1994 dan undang-undang lain. Bahagian kaedah menerangkan aspek-aspek

yang dinilai seperti kualiti udara dalam bangunan, kadar kebisingan dan

pencahayaan. Alat-alat yang digunakan untuk mendapatkan semua bacaan ialah

pengukur kebisingan, pengukur pencahayaan dan pengukur kualiti udara dalam

bangunan. Dalam bahagian penganalisisan data, perbandingan akan dibuat antara

data yang diperoleh dengan nilai piawai untuk setiap bidang. Selain itu, cadangan

untuk memperbaik kelemahan-kelemahan turut dinyatakan dalam bahagian ini.

CHAPTER 1

INTRODUCTION

1.0 Introduction

Nowadays, people can see safety and health aspect play a major role in all

industries. Company cannot afford to lose much more skilful worker in they have.

When they lose some experienced worker, they will suffer some decreasing of

productivity because they will use new worker and in the same time they need to

train them. In the other hand, they must pay some compensation to the worker due to

the accident.

By referring to this condition, in 1994, Parliament of Malaysia has agreed to

establish an act which know as Occupational Safety and Health Act 1994. This act is

established to create a safety and comfortable working area in industry.

In this act, there is something that can help all workers prevent themselves

fiom hazard which is ergonomic factor. Ergonomic is defined by Karapetrovic

(1999); information about human behaviour, limitation, abilities and other human

characteristic to the design of system for efficient , safe, comfortable and effective

human use.

This project or research is to evaluate and improving for facilities compliance

with OSHA's ergonomic regulations in manufacturing industry. This chapter will

discuss about the objectives of the research, scope of the project, problem statement,

important of the study and outline of the study.

1.1 Problem Statement

OSHA's Ergonomic Regulation is needed to be understood by all industries

due to many reasons. It is related fbr many safety and health issues in working area.

Nowadays, many industries have applied these regulations but not all the workers

know about the existence of it. Basically workers cannot understand the act stated

and level of implementation among workers is low. Most of workers ignore safety

procedures which been ruled by company due to lack of knowledge. This research

tries to understand and identifl the level of implementation in one of manufacturing

industry and how to simplify it so that it can be understood by all workers. Besides

that, this research also tries to discover relation with safety and health issues in the

industry and how it relate in increasing the productivity in the industry.

1.2 Objectives

The objectives of this research are:

i. To understand OSHA's Ergonomic Regulations in manufacturing

industry.

ii. To construct OSHA's Ergonomic Regulations Assessment Guide.

iii. To evaluate and implement OSHA's Ergonomic Regulations in

manufacturing industry.

iv. To analyse the efficiency and benefit of implementations.

1 3 Scope of the Research

This project is to define the OSHA's Ergonomic Regulations and a case study

selected for implementation and analyse in the manufacturing industry. This study

has been done in Ingress Precision Sdn. Bhd. (IPSB) which is situated in Nilai,

Negeri Sembilan. This factory is one of the vendors for PROTON and PERODUA

which they supply door sash and moulding parts. This research has covered only in

sash manufacturing. This research will base on sound or noise level, indoor air

quality and illumination.

1.4 Important of the Research

This research is very important to survey the need of OSHA's Ergonomic

Regulations in industry. This research also can help the industry which applies

OHSAS 18000's certificate which is related to safety and health in the working area.

But the most important of this research, people could see how they can avoid

accident in industry and all the elements that can make accident occur. Besides that,

people can see some benefit of implementation in the industry whether in

productivity or the efficiency of the worker.

1.5 Outlined of the Research

This report consists of five chapters which are introduction, literature review,

methodology, data collection and data analysis. In the introduction, it is discuss on

overview of the research, problem statement, scope of the research and important of

the report.

In the literature review, it explains on previous research which related to the

research to be done and the hypothesis of the all study.

In the methodology, all the method to accomplish the research will state. All

the experimental and analytical method will describe in this part.

In data collection, it will discuss how to setup the experiment, the data that

need to collect and the result prediction of the research.

CHAPTER 2

LITERATURE REVIEW

2.1 Overview of the Research

In creating a safety and healthy working area, there are many aspects that

company must consider. In ergonomic study, there some factors that contributes to

accidents which are personnel characteristic, job characteristic, equipment and tools,

physical environment and social environment. (Wickens et al, 2004)

In personnel characteristic, there are some factors that must be considered

whch are age and gender, job experience and stress, fatigue, drugs and alcohol.

From the research, people fiom 15 to 24 years old, have highest rates in accident.

The primary reasons is people who get older become more conservative and their

estimation to accident become more conservative. For job experience, high

percentage of accidents occur to the worker who has been work fio first three month

with peak about two or three month. In this case, experience worker can identify the

hazard easily compare to the new worker. Workers who works in stress and fatigue

will have decrement in performance an expose them to injury. For the person who

taking alcohol or drug before works, he will lose much of their attention and

awareness for their work. This also exposes them to the accident. (Wickens et al,

2004)

Many characteristics of the job or task that can cause difficulties for the

operator. Some oh these include high physical workload, high mental workload and

other stress including factor such as vigilance task that lower physical arousal level.

(Wickens et al, 2004)

Many of the hazards associated with the workplace are localized in the tools

or equipment use by the employees, and as a consequence, much of the safety

analysis performed in an industrial environment focuses on hazard inherent in the

equipment itself Accidents cause by equipment normally due to control and display,

electrical, mechanical, pressure and toxic hazard. Good control and display are

desirable to detect any hazard at the equipment. Electric hazard occur due to electric

shock in a sudden and accidental stimulation of the body's nervous system by an

electric current. Mechanical hazard occur can come fiom many source such as

rotating equipment, open-generate power presses and power hammer. There are

some accidents due to mechanical hazard such as cutting or tearing of skin, muscle

or bones, shearing, crushing, breaking and straining. The entire mechanical hazard

could be reduced by applying guard at the potential area. Toxic and pressure hazard

can cause from altitude change, heat, pressurize gas and many more. It can cause

vessel to rupture. (Wickens et al, 2004)

In physical environment, elements that can cause accident are illumination,

noise and vibration, temperature and humidity, fire hazard, radiation hazard, fall and

exits and emergency evacuation. Lighting most directly affects safety by making its

relatively easy or difficult to perform task. Illumination is important for safety

include direct and indirect glare and light or dark adaptation. Noise and vibration can

cause us to deaf and cannot hear any sound signal to avoid hazard. Working

condition with too high or low temperature can expose body to serious safety hazards

either directly by impacting body health or indirectly impairing operator

performance. Fire hazard come Erom combination of three elements: fhel, oxidizer

and source of ignition. Fire hazard can burn anythmg close to it. Certain

combinations of the neutrons and protons can results unstable atoms, which try to

become stable by giving off excess energy in the form of particles wave (radiation).

The examples of elements that can produce radiation are X-ray, gamma ray and

thermal neutron. Biological effects of radiation can occur in a one-time acute

exposure or fiom chronic long-term exposure. Falls can be cause by falling due to

slippery, fall from one floor to another, falling from a structural support or walkway,

fill from building and hll fiom ladder. Exits and emergency evacuation poles or area

which is also can cause hazard. When there are any accidents occur in the building,

and no emergency door, it can cause much more danger. (Wickens et al ,2004)

Social environment can cause accident. This is due to other work that we

cannot see during doing other work and lack of human awareness. (Wickens et al,

2004)

From the entire causes which been stated above, this research will focus on

the physical environment aspects at three elements which are illumination, noise and

indoor air quality. All this elements must be related and based on OSHA's

ergonomic regulations.

Occupational Safety is a branch of Occupational Safety and Health that is

concerned with the physical environment of the workplace and the wellbeing of the

worker. Its aim is to create a conducive environment through safe work practices,

procedures and Occupational Safety and Health (OSH) management systems to

ensure the protection of workers while doing their job tasks. The Occupational

Safety Division of National Institute of Occupational Safety and Health (NIOSH)

division is currently involved in several consultation projects and in-house training

for various sectors like manuficturing, transport, construction and agriculture.

(WHO/ILO, 1950)

Occupational health is the promotion and maintenance of the highest degree

of physical, mental and social well being of workers in all occupations, the

prevention among workers of departures fiom health caused by their working

conditions, the protection of workers in their employment fiom risks resulting fiom

factors adverse to health, the placing and maintenance of the workers in an

occupational environment adapted to his physiological and psychological equipment.

(ILO/WHO, 1950)

December 1,1992 marked a new era in d ~ e promotion of Occupational Safety

and Health in Malaysia. On this day the National Instihtte of Occupational Safety

and Health (NIOSH) was launched, after careful preparation and commitment from

all parties to improve the safety and health of workers at the workplace in Malaysia.

In the words of the Minister of Human Resources, Malaysia, NTOSH would be a

"critical catalyst" in the promotion of occupational safely and health that would also

serve as the "backbone" to create a "self-regulating occupational safety and health

culture" in Malaysia.

NIOSH was established as a Company Limited by Guarantee, under the

Malaysian Companies Act, 1965. As a company, NIOSH is expected to operate

efficiently and with minimal administrative bureaucracy. The NOSH Board of

Directors comprises of 15 Board members, ten of which are appointed by the

Government wllile the remaining are elected by NIOSH members during the Annual

General Meeting (AGM). This makes NIOSH different from similar institutions in

other countries. NIOSH was set up with a Rhll million Launching G m ~ t from the

Government and a further W 5 0 million Endowment Fund (RM40 million from the

Social Security Organization (SOCSO) of Malaysia and a fiuther RM 10 million

fiom the Malaysian Government), which will be invested, and the rehun of

investment will be used to partly finance the operation of NIOSH. (NIOSH, 2002)

The definition of ergonomic base on NIOSH, 2002:

The science on how to fit the task and working environment to the worker

using scientrfic data

Wilson 1995 defined ergonomic as "the practice of learning about human

characteristic and then using that understanding to improve people 's interaction

with the things they use and the environments in which they do so."

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Table 2.2: OSHA's regulations (Continue)

Code of Practice On Indoor Air Quality

Refer to Checklist of Ergonomic Evaluation

INDOOR AIR QUALITY

1. Employer should assess the risk arising from the indoor air quality at the place of work to the health of his employee.

2. An employer should ensure that his employee or any other occupants at the place of work are not exposed to any of the contaminants listed in table 1 exceeding the corresponding maximum limits. 3. The assessment should be carried out during normal business activity and must take into consideration the following.

Source of indoor air contaminants. Employee's exposure to environmental tobacco smoke Employee's exposure to air contaminants, either fi-om indoor or outdoor source. The prescribed activities. The adequacy of mechanical ventilation at the work place of work. The necessity to monitor an employee's exposure; and The necessary actions to be taken to improve the indoor air quality at the work place of work.

Table 2.2: OSHA's regulations (Continue)

Factory and Machinew Act 967, Extech Instrument Standard

Refer to Checklist o f Ergonomic Evaluation

LIGHTING

I . Seseorang tidaklah boleh dihhendaki atau dibenarkan beketja &lam mana-mana bangunan kilang jika daya memasukan cahaya semulajadi kurang dari sepuluh peratus daripada kelusan lantai bangunan itu.

2. Semua tingkap dan tingkap bumbung hendaklah: () ditempat dan dijarakkan sedernikian supqa hadaan cahcrya matahari di tempat kerja sama cerah pada keseluruhan kuwasan kerja. (I!, sentiasu dibersihk-an pada pennukaan-permukaan luar don dalamnya dan sentiasa bebas dan'pada apa-apa halangan.

3' Da'am tiaP-tiaP bahagian bangunan, keamatan penyinaran tidak boleh kurang daripada dua kakr dian sekaki diukur pada dataran mengufik setinggi tiga kaki dari aras lantai atau aras kerja dan tidak kurang daM'pada lima batang dian sekaki pada mana-mana tempat di mana kerja sebenamya dilakukan.

4. Keamatan penyinaran diukur pada aras lantai ddam mana- mana kilang di mana seseorang lalu lalang tidak boleh kumng daripada setengah batang dian sekaki.

23 Previous Research

Table below tells about some study which been made by other person which

quite significant with this research.

Table 2.3: Summary of Previous Research

Descri

I

(Diley and Kliner, 1996) The research is all about up and down on the job could

cause an accident. It also talk about the right that

workers have in OSHA also the liability that safety

officer must cany on. It also tells about employees

duties under OSHA. Besides that, the management

should create safety culture in the working area.

(Kearney, 1995) This research is about to plan facilities compliance with

OSHA's Ergonomic Regulations and it is more about

worker's compensation. It also tell about the relation

between OSHA and ergonomic. It also brief about how

to plan compliance and the person involved.

(Govindaraju, Pennathur, This journal is about how to improve the quality of

Mital, 2000) manufacturing based on case study that they give. The

case study related more on ergonomic.

(Hartford, 2001) This study is more about to understand the needs of

OSHA and how OSHA can help employer and

employees to create safe working area.

(Robert,1999) This journal tells about the history of OSHA It also

tells about six OSHA elements and alternative policy

2 3 Summary

By studying all the source that collected, OSHA is an act that need to be obey

due to it policy to create safe working area and could help company to increasing

productivity and working efficiency. Failure to obey this law can cause the company

will charge in the court. This act also has regulations related to ergonomic which

help worker work safely and help company to create safety area although there are

many job and heavy machines around them.

CHAPTER 3

METHODOLOGY

3.1 Overall Research Methods

To accomplish this research, all the methods to get the data and to analyse

must be setup in proper way. In this chapter, all the methods from getting the title

until the conclusion will be discussed.

First, the title had been gathered from the lecturer and the lecturer will assign

as the supervisor to guide this research. After getting the title, lecturer had brief the

title and how the research will be done and the goal of the research.

Then, the research had been started by searching for the journals and books

which related to the study. All this sources is usefbl as guideline to the research and

to get more information about this title. It also useful to understand the title and the

research needs to accomplish the research.

Besides searching all the data by using book and journal, the data also had

been gathered in short course which been held in Ingress Precision Sdn. Bhd.(IPSB)

in Nilai, Negeri Sembilan. This course was held for the staffs as preparation for audit

from SIRIM to evaluate the company for IS0 14000 and OHSAS 18000 certificates.

After getting all the sources, the research had start with writing the

introduction of the research. In introduction, all about the project will be discussed

and we can see the scope of the research. The research is continued with literature

review. This is to review all the previous research and the delinition of the research.

Then the methods to get the data will be discussed in methodology chapter.

Here the method on how to get the data will be explained. Data needed are sound

level, illumination and indoor air quality. Sound level will be collected using sound

level meter. Data will be gathered fiom three different spot at the line. Then, the data

will be checked and got the average. From this data, comparison with standard of

sound level will be making by comparing data with standard in Machinery and

Factory act. Illumination will be collected using light meter. Same as sound level,

data collected in 3 different spot. After get the data and average of data, comparison

will be made with three standards which are Company standard, light meter standard

and Machinery and Factory act standard. Indoor air quality will be collected using

indoor air quality monitor. The monitor will be placed at centre of the line. Data that

monitor collected are carbon dioxide, carbon monoxide, humidity, volatile organic

compound and temperature. Standard that used to compare with data collected is

Code of Practice Indoor Air Quality by Ministry of Human Resource Malaysia. After

that, it will continue with data collection. For indoor air quality, data will take only

once in one line. Sound level and illumination data will be collected three times fi-om

different spot. For sound level, data can be collected at the machines that can give

high level of sound. For illumination, data can be gathered at the machine at the

place operator done his work.

Data analysis study shows us the result of the research and the status of the

study. From data analysis, data can be compared and the graph of each section of

research can be look. In data analysis, the effect of the result also can be highlighted.

Discussion will be focused on obstacle during doing the research and how to

implement OSHA's ergonomic regulation and the right way to do it. Conclusion is

summarized of the research and what expectation of the result gathered.

Data 1 Referent tions

3.2 Experimental Methods.

Measurinl

Equipmen

In this research, three data has been collected. Here, all the method to run this

research has been shown. All data will be recorded in the table. All tables consist of

minimum and maximum value and average. For illumination and noise level, the

table consist of three reading. For indoor air quality table, it has five readings which

are carbon monoxide, carbon dioxide, humidity, volatile organic compounds and

temperature. After getting all average data, the data has been compared with standard

data to state the status. From the status of the data, the recommendation will be made

and done.

Average Sound Sound Level Sound Level Meter

Level

Average Illumination Light Meter

Illumination level

Level of Carbon

Dioxide, Carbon Indoor Air Quality

Indoor Air Quality Monoxide and Monitor

Volatile Organic

compound

--

Factory and

Machinery Act

1967

Extech Instrument

Standard

.

Code of Practice

Indoor Air Quality

3.2.1 Noise or Sound Level

To get this data, equipment that been used is sound level meter to measure

the noise level. This experiment covers only in 16 lines. Each line, three reading has

been taken and the average reading has been calculated. This equipment measures

the minimum and maximum reading for each time. This measurement gives reading

in decibel (dB) unit. After get all the average reading, the data has been compared

with Permissible Exposure Limits which consist in Factories and Machinery Act and

Regulation. Refer to Appendix A.

3.22 Illumination

To get this data, illumination meter has been used to get illumination level.

This equipment use lux as the unit. To use the equipment, it must be switched on and

set the equipment to read data fiom fluorescent bulb. It gives minimum, maximum

and average reading. Here, take three reading has been taken and get the average

data. After all the data collected, it has been compared with Extech Instrument

Standard. Refer to Appendix A.

3 2 3 Indoor Air Quality

To fulfil this experiment, indoor air quality monitor equipment has been used.

To use it, make sure it has been calibrate in the place with good air quality such as

recreational forest. It can measure carbon dioxide, carbon monoxide, humidity

temperature and other gas or particle level in certain area. It gives minimum and

maximum value for each reading. Refer to Appendix A.

3 3 OHSAS 18000 COURSE

This certificate is to recognize a company afford to follow the rules and

which contain in OHSAS 18000 needs. All the company which want this

certificate, they need to apply from SIRIM or other body. They must follow all the

procedures that contained in it terms and conditions. All the workers must attend

OHSAS training which conducted by outside consultant or by certified safety officer.

This is one of the terms that they must obey. In OHSAS 18000 there are many

aspects that they need to follow. The company need to identifjr the entire hazard in

their compound and hazard source. The entire hazard area must be labelled with

special signage. They also need to occupy they plant with accident report form. This

is to record all the accident which been occurred in the plant. In this course, there are

some explanations that relate to this research. It talks about sound level, illumination

and indoor air quality which need to be obeyed by the company which want the

certificate.

3.4 Limitation

There is a limitation that which been faced during conducting these

experiments. First of all, to collect data, the data before machine starting operations

is needed. This is to seek the situation or condition without operation and to detect

any out source. For example, the sound level of the machine before and during

operation is different. Before operation, the sound is may be low, but the sound of

the surrounding is needed to check whether it contributes to the increasing of sound

level. Here the difficulty to get data without machines operate is impossible because

the production is continuous 24 hours a day.

CHAPTER 4

DATA COLLECTION

4.1 Setting up Data Collection

To set up data collection, first, review of the factory must be considered. In

IPSB, there are 17 lines with variety of machine are existence. The machines that

place in IPSB are press machine, roll forming machine, plasma welding, machine,

metal saw cutting machine, bending machine, stretch bending machine, rotary

bending machine, oil press machine, drilling machine, overhead crane and antirust

machine.

This factory has two companies and IPSB is selected. This is the border of

the study. The equipments that will use are sound level meter, illumination meter and

indoor air quality monitor. Thls company is chosen due to product that it produce

which is more complex with use of many heavy machines and more danger.

4.2 Table for Data Collection

To collect all the data, three tables has been setup. These tables are used to

collect reading for three experiments which are sound level, illumination level and

indoor air quality.

For these three tables they have column for lines, reading, maximum and

minimum value and average. These tables consist of 17 production lines in IPSB.

Each table will have three columns for reading at each line. Each line has three

reading. Average value fio each line will be calculated by adding those three value

and divide the total value with three. Below is the sample of the equation:

Average = (reading1 + reading2 + reading 3 1 3

After getting all the average of each reading, the value will be compared with

the standard data. Here, the status of each line will be recognized. Here the company

can setup the countermeasure to overcome any problem for each line. Table which

been constructed can be referred to Appendix A.

After knowing the status of each line, the experiment will continue to identi@

the critical area and need to by modi@ due to OSHA need. Below are standards that

will be used to compare all data.

Table 4.1: Standard for Sound Level (Factory And Machinery Act 1967)

Duration Permi8 (hour:

sure .aY