SIMPLIFY NOTES OCCUPATIONAL SAFETY AND HEALTH FOR PROCESS ENGINEERING AUTHORS: Nor Hakimah binti Ahmad Subri Mohamad Fikhri bin Nor Azman Nuraiman bin Abd Rahman
SIMPLIFY NOTES OCCUPATIONAL SAFETY AND HEALTH FOR PROCESS ENGINEERING EDITION 2024 i
AUTHORS Ts. NOR HAKIMAH BINTI AHMAD SUBRI MOHAMAD FIKHRI BIN NOR AZMAN NURAIMAN BIN ABD RAHMAN EDITOR HAFIZAH BINTI NAIHI DESIGN MUHAMMAD BILAL BIN MOKHTAR ii
COPYRIGHT POLITEKNIK KUCHING SARAWAK MINISTRY OF HIGHER EDUCATION KM22, JALAN MATANG, 93050 KUCHING, SARAWAK. Phone No. : (082) 845596/7/8 Fax No. : (082) 845023 E-mail : [email protected] Website : http://www.poliku.edu.my/ Copyright © 2024 Politeknik Kuching Sarawak eISBN 978-629-7638-25-6 All rights reserved. No parts of this publication may be copied, stored in form or by any means, electronics, mechanical, photocopying and recording or otherwise or by any means for reproduced without the prior permission of Politeknik Kuching Sarawak. Published by: Politeknik Kuching Sarawak Ministry of Higher Education iii
PREFACE Simplify Notes Occupational Safety and Health for Process Engineering is designed to impart understanding of the self-regulatory concepts and provisions under the Occupational Safety and Health Act (OSHA) in Malaysia. Special thanks to Ketua Jabatan Kejuruteraan Petrokimia Politeknik Kuching Sarawak, En. Khalid Husseine bin Tuah especially in facilitating the completion of this book. The purpose of this book is to stress the responsibilities of workers in implementing and complying with the safety procedures at work. Understanding of notifications of accidents, dangerous occurrences, poisoning and diseases. This book will also provide an understanding of the key issues in OSH Management, Incident Prevention, Chemical Safety, Hazard Identification Risk Control and Risk Assessment (HIRARC), Fire Safety, Workplace Environment and Ergonomics and guide the students gradually into this multi-disciplinary science. Despite the stringent efforts, the book may not be free from few errors, technical or otherwise. There is always a scope for the improvement. The authors therefore will be grateful to all of those who bring errors to their notice. Suggestions made for the improvement are most welcome. Ts. Nor Hakimah Binti Ahmad Subri Mohamad Fikhri Bin Nor Azman Nuraiman Bin Abd Rahman Jabatan Kejuruteraan Petrokimia Politeknik Kuching Sarawak v
ABSTRACT In general, Simplify Notes Occupational Safety And Health For Process Engineering’s book is designed to impart understanding of the self-regulatory concepts and provisions under the Occupational Safety & Health Act (OSHA) in Malaysia. This book presents the responsibilities of workers in implementing and complying with the safety procedures at work. Understanding of notifications of accidents, dangerous occurrences, poisoning and diseases and liability for offences will be imparted to students. This book will also provide an understanding of the key issues in OSH Management, Incident Prevention, Chemical Safety, Hazard Identification Risk Control and Risk Assessment (HIRARC), Fire Safety, Workplace Environment and Ergonomics and guide the students gradually into this multi-disciplinary science. This book is designed simply to make it easier for students to remember the main points related to safety and health at work and be able to apply them while working later. Using a large font will make it easier for lecturers to use this book as teaching material in class. Notes are also summarized in point form and include related diagrams that will help increase memory related to a topic studied. The Interactive Button was created to create two-way communication between lecturers and students Finally, there is a formative assessment to make it easier for lecturers to assess students' understanding when a topic after teaching is done. Keywords: Safety, Health, Occupational, Engineering Process vi
ABSTRAK Secara umumnya, buku Simplify Notes Occupational Safety And Health For Process Engineering dihasilkan untuk memberikan pemahaman tentang konsep dan peruntukan kawal selia kendiri di bawah Akta Keselamatan & Kesihatan Pekerjaan (OSHA) di Malaysia. Buku ini menerangkan tanggungjawab pekerja dalam melaksanakan dan mematuhi prosedur keselamatan di tempat kerja. Penekanan tentang pemberitahuan kemalangan, kejadian berbahaya, keracunan dan penyakit serta liabiliti untuk kesalahan akan diberikan kepada pelajar. Buku ini juga akan memberikan pemahaman tentang isu-isu utama dalam Pengurusan OSH, Pencegahan Insiden, Keselamatan Kimia, Kawalan Risiko Pengenalpastian Bahaya dan Penilaian Risiko (HIRARC), Keselamatan Kebakaran, Persekitaran Tempat Kerja dan Ergonomik disamping membimbing pelajar secara beransur-ansur ke dalam bidang ini . Buku ini direka bentuk seperti ini untuk memudahkan pelajar mengingati perkara-perkara utama berkaitan keselamatan dan kesihatan di tempat kerja serta dapat mengaplikasikannya semasa bekerja nanti. Penggunaan saiz tulisan yang besar akan memudahkan pensyarah menggunakan buku ini sebagai bahan pengajaran di dalam kelas. Nota juga diringkaskan dalam bentuk point dan termasuk gambar rajah berkaitan akan membantu meningkatkan ingatan berkaitan topik yang dipelajari. Butang Interaktif diwujudkan bagi mewujudkan komunikasi dua hala diantara pensyarah dan pelajar. Akhir sekali,disertakan penilaian formatif bagi memudahkan pensyarah menilai kefahaman pelajar apabila sesuatu topik selepas pengajaran dilakukan. Kata kunci: Kesihatan, keselamatan, Pekerjaan, Kejuruteraan Proses vii
TABLE OF CONTENT PAGE TITLE i COPYRIGHT iii PREFACE v ABSTRACT vi ABSTRAK vii CHAPTER 1: Introduction to Occupational Safety and Health in a Workplace 1 1.1 Concept of Occupational Safety and Health (OSH) 2 1.2 Duty of care 8 1.3 Incident prevention 13 1.4 Statutory requirements 20 CHAPTER 2: Occupational Safety and Health Management System 26 2.1 Concepts of safety management 28 2.2 Safety and health committee 36 2.3 Roles of the management 39 CHAPTER 3: Chemical Safety 45 3.1 Chemical regulations under Act 514 46 3.2 Safety data sheet of hazardous chemicals 53 3.3 Register of chemicals hazardous to health in workplace 59
CHAPTER 4: Hazard Identification, Risk Assessment and Risk Control (HIRARC) 74 4.1. Definition hazard, risk and danger 76 4.2. Types of hazard 79 4.3. Risk assessment 81 4.4. Risk control 86 CHAPTER 5: Fire Safety 92 5.1 Basic of fire 93 5.2 Fire safety planning 100 5.3 Escape route 105 CHAPTER 6: Workplace Environment and Ergonomics 108 6.1 Workplace environment 109 6.2 Workplace ergonomics 115 6.3 Statutory requirements 125 REFERENCES 130
1 CHAPTER 1 Introduction to Occupational Safety and Health in a Workplace Learning Objectives: At the end of this chapter, you should be able to: • Explain the concept of Occupational Safety and Health (OSH) • Explain Employer’s responsibilities (Part IV, Section 15-19) and Employee’s responsibilities (Part VI, Section 24-27) • Apply incident prevention • Express statutory requirements Factory and Machinery Act 1967 and Environment and Quality Act 1974 legislation Author : Ts. Nor Hakimah binti Ahmad Subri
1.1 CONCEPT OF OCCUPATIONAL SAFETY AND HEALTH (OSH) • Malaysian’s OSH legislations history • The Selangor Boiler Enactment 1892 • The Perak Boiler Enactment 1903 • The Pahang Boiler Enactment 1908 • The Negeri Sembilan Boiler Enactment 1908 • Federal Machinery Enactment 1913 • Machinery Ordinance 1953 • Factories And Machinery Act 1967 • Occupational Safety And Health Act 1994 Figure 1.0 Hiroshima Sungai Buloh Figure 1.1 Hiroshima Japan 2
Figure 1.3 Tripartite Process Approach 3
Objective of Occupational Safety and Health (OSH) • DEFINITION-The promotion and maintenance of the highest degree of physical, mental and social well-being of workers in all occupations (ILO,WHO) • AIM-Prevent illness, injury, and disease due to working conditions (OASH) • CONCEPT-OSH is a basic human right for safety at workplace -OSH means providing a working environment which is conducive to safety & health. 4
OSH legislation • OSHA in Malaysia is an Act which provides the legislative framework to secure the safety, health and welfare among all Malaysian work forces and to protect others against risks to safety or health in connection with the activities of persons at work. • Gazetted on 24th February 1994. • The Act contains 67 sections, divided into 15 parts and appended with 3 schedules. • The first three parts state the objects of the Act and provide the infrastructure for appointment of officers and the National Council (Majlis Kebangsaan). • Part IV(4) to VI(6) provides the general duties for those who create the risks e.g. employer, self-employed person, designer, manufacturer, supplier, etc. and those who work with the risks i.e employees. 5
OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) 6
Objectives of Occupational Safety & Health Act 1994 (Act 514) • Secure the safety, health and welfare of persons at work against risks to safety or health arising out of the activities of persons at work. • Protect person at a place of work other than persons at work against risks to safety or health arising out of the activities of persons at work. • Promote an occupational environment for persons at work which is adapted to their physiological and psychological needs. • Provide the means whereby the associated occupational safety and health legislation maybe progressively replaced by a system of regulations and approved industry codes of practice operating in combination with the provisions of this Act designed to maintain or improve the standards of safety and health. 7
1.2 DUTY OF CARE Employers Employees 8
Employer’s responsibilities (Part IV, Section 15- 19) • Provide a workplace free from recognized hazards and comply with OSHA standards • Provide training required by OSHA standards • Keep records if injuries and illnesses • Provide medical exams when required by OSHA standards and provide workers access to their exposure and medical records • Not discriminate against workers who exercise their rights under the Act (Section 11(c) • Provide and pay for Personal Protective Equipment (PPE) 9
PENALTY Fine <RM50K @ Imprisonment<2 Years @ Both ‘Responsibility for safety and health in the workplace lies with those who create the risks (employer) and those who work with the risks (employees)’ Guidelines on OSH Act 1994-2006 Figure 1.4 Employer’s Responsibility 10
Employee’s responsibilities (Part VI, Section 24-27) • Ensure personal safety and that of others • Cooperate with employer and others • Properly wear and/or use PPE that are provided • Comply to any safety instructions • Right to hazard exposure and medical records • Right to file a complaint with OSHA • Right to participate in an OSHA inspection • Right to be free from retaliation for exercising safety and health rights • Worker responsibilities 11
PENALTY Fine <RM1K @ Imprisonment<3 Months @ Both Figure 1.5 Employee’s Responsibility 12
1.3 INCIDENT PREVENTION 13
Concept incident and accident • DEFINITIONAccident is an event that has unintentionally happened, that results in damage, injury or harm. Incident/Near miss is an event that has unintentionally happened, but this may not result in damage, harm or injury. “Therefore, every accident can be an incident. However not all incidents can be termed as an accident” Incident Prevention is a process investigates developing a safe workplace to minimize the possibility @ zero possibility of being injured at the workplace 14
INCIDENT VS ACCIDENT “The Bhopal disaster or Bhopal gas tragedy was a chemical accident on the night of 2–3 December 1984 at the Union Carbide India Limited (UCIL) pesticide plant in Bhopal, Madhya Pradesh, India. Considered the world's worst industrial disaster,[3] over 500,000 people in the small towns around the plant were exposed to the highly toxic gas methyl isocyanate (MIC).” Incident/Near miss Accident Disaster Figure 1.6 Incident, Accident, Disaster 15
Model accident theory – Henrich’s Domino Theory The unsafe act and mechanical hazard constitute the central factor in the accident sequence The removal of the central factor makes the action of preceding factors ineffective Figure 1.7 Henrich’s Domino Theory 16
• Heinrich’s theory is weak and negative • Blaming victim and lack system thinking, continual • Improvements, upstream control and worker participation. Figure 1.8 Heinrich’ Theory Weakness 17
Model accident theory- Birds Loss Theory In line with Schewhart(1930’s) theory of quality control. Figure 1.9 Bird Loss Theory 18
Important incident prevention in a workplace (Ice-berg Theory) Benefits of incident prevention to company • Higher productivity. • Increased efficiency & quality. • Reduced medical & insurance costs. • Lower workers’ compensation rates & payment. • Improved reputation as an employer of choice. Figure 1.8 Accident Cost Iceberg 19
1.4 STATUTORY REQUIREMENT 20
Objective of Factory and Machinery Act (FMA) 1967 • To provide for the control of factories with respect to matters relating to the safety, health and welfare of persons • The registration and inspection of machineries 21
TABLE 1.0 FMA 67 vs. OSHA 94 Act FMA 1967 OSHA 1994 Known as Act 139 Act 514 Application -Prescriptive -Too dependent on government -Self regulations -Responsibilities to employer and employees -Consultation Scope Only factories & machinery Occupational (as per Schedule 1) Exception -On board ships -Armed Forces -On board ships -Armed Forces Department/Enforcement Factory & Machinery Dept DOSH Training & Research - NIOSH Regulations 11 Safety 4 Health 2 Amendment (2004/05) 9 Policy/SHO/Chemical Guidelines - 49 (till end 2011) Figure 1.8 FMA 22
Objective of Environment and Quality Act (EQA) 1974 legislation and enforcement • To prevent, abate, control of pollution and to enhance the environment, and for purposes connected therewith. • The rationale are to address possible impact on human health as a result of increasing industrialization process. To establish a comprehensive legal framework to deal with environmental problems 23
Figure 1.9 EQA Table 1.1 DOE and EQA limit 24
FORMATIVE ASSESMENT 1. What does OSH stands for? a. Organized Service & Health b. Occupational Safety & Sound c. Overactive Safety & Health d. Occupational Safety & Health 2. Which of the following is TRUE under OSHA law? a. Employees must purchase all protective equipment at their own cost. b. Employees must find safety training that they can take on their personal time. c. Employers must provide safety training to employees at no cost. d. Employees may choose what safety equipment they need and whether or not they want to wear it to be in compliance. 3. Which one is NOT related to OSH? a. Occupational Safety b. Occupational Hygiene c. Occupational Therapy d. Occupational Health 4. Which authorities does NOT involve in OSH a. Construction Industry Development Board Malaysia (CIDB) b. Department of Social Welfare Malaysia c. Ministry of Health Malaysia (KKM) d. Department of Occupational Safety & Health (DOSH) 25
26 CHAPTER 2 Occupational Safety and Health Management System Learning Objectives: At the end of this chapter, you should be able to: • Explain the concepts of safety management • Discuss the establishment of safety and health committee • Write roles of the management Author : Ts. Nor Hakimah binti Ahmad Subri
INTRODUCTION • Workplace injuries are preventable. • A Safety and Health Management Systems is the best defense against workplace injuries. Safety and Health Management Systems 27
2.1 CONCEPTS OF OCCUPATIONAL SAFETY AND HEALTH MANAGEMENT SYSTEM (OSHMS) Definition- • A OSHMS is a systematic approach to managing safety and health activities by integrating occupational safety and health programs, policies, and objectives into organizational policies and procedures. • OSHMS is a set of safety and health program components that interact in an organized way. Example-Respiratory System An orderly set of components that work together for a certain purpose Figure 2.0 Respiratory System 28
Benefits apply OSHMS • Reduce the number and severity of work- related accidents and illnesses. • Managers and employees can work together • Proactive approach • The benefits: fewer lost work days, lower workers' compensation costs and higher employee morale and productivity 29
Five primary elements to an effective OSHMS • Management Commitment • Employee Involvement • Workplace Analysis • Hazard Prevention and Control • Safety and Health Training 30
Characteristics of an Effective OSHMS • Adaptability and ease of use • Needs to be used and understood by all employees • During development, keep in mind those with disabilities who may need various methods of understanding the system • Easy to understand and implement • OSHMS should be adaptable to allow changes and improvements in your organization. • In an effective OSHMS, employees look for ways to make their work environment safer for themselves and their coworkers. 31
OSH standard OSHMS 32
Principles of OSHMS Figure 2.1 OSH Elements Figure 2.2 Implementation Framework 33
POLICY • An OSH policy is a written document which expresses the organization’s commitment to employees health, safety and well being • It is a foundation for the efforts taken to provide a suitable working environment • policy and standards are guidance or management information documents • any company has a social and legal obligation to provide a safe and health working environment to all his employees. ACT 514 OCCUPATIONAL SAFETY AND HEALTH ACT 1994 PART IV-GENERAL DUTIES OF EMPLOYERS AND SELF EMPLOYED PERSONS Duty to formulate safety and health policy. Except in such cases as may be prescribed, it be the duty of every employer and every self-employed person to prepare and as often as may be appropriate revise a written statement of his general policy with respect to the safety and health at work of his employees and the organization and arrangements for the time being in force for carrying out that policy, and to bring the statement and any revision of it to the notice of all of his employees. 34
A Good Policy • The policies provided must be tailored to the specific organization. • The policy statement must have the employer's certification. A certification that can be in the form of the employer's signature and name or stamp and so on is required to confirm that the employer agrees and is responsible for all statements stated in the policy. • The policy statement should be dated. The date, signature and name of the person responsible for the policy statement are crucial in the effort to review the policy and ensure it is relevant. The need to review policy becomes a legislative necessity Reasons why occupational safety and health policies are provided. I.it is mandatory through the provisions of the law (section 16, OSHA 1994). II.it is necessary to express to all members of the organization (employers and employees) a joint commitment to provide a safe and healthy workplace. EXAMPLE Figure 2.3 OSH Policy 35
2.2 ORGANIZING-ROLE OF MANAGEMENT Safety And Health Committee “Section 30 of OSHA 1994 stated that every employer shall establish a safety & health committee at the workplace” OSHA 1994 OBJECTIVE a)To enhance cooperation and consultation between employers and employees in improving safety and health at workplace b)To establish a two-way communication channel to provide information related to occupational safety and health c)To increase the interest and motivation of all groups d)Management and employees in issues related to occupational safety and health 36
Safety committee OSHA (2022) Director General: Ybhg. Dato’ Ir. Mohtar Bin Musri Department of Occupational Safety and Health, Ministry of Human Resource-2020 • Section 30 of OSHA 1994 (1) stated that every employer shall establish a safety and health committee at the place of work in accordance with this section if: a)There are forty or more persons employed at the place of work; or b)The Director General directs the establishment of such a committee at the place of work. Figure 2.4 Director General 37
Composition of committee < 100 EMPLOYEES: MINIMUM 2 REPRESENTATIVE EACH > 100 EMPLOYEES: MINIMUM 4 REPRESENTATIVE EACH LET ALL SECTIONS BE REPRESENTED, INCLUDING WORKSHOP. Figure 2.5 OSH Organization 38
2.3 Role Management of committee POSITION FUNCTION CHAIRMAN an employer or his authorized manager • Prepare agenda for next meeting • Arrange for meeting place • Notify members of meeting • Arrange program • Set time schedule for meeting • Arrange all seating for members • Review previous minutes and material for meeting • Conduct meeting SECRETARY safety and health officer or appointed by the chairman or appointed among the members • Record minutes of meeting ( Minutes kept for 7 years for purposes of inspection by an OSH officer ) • Distribute minutes to committee members ( Minutes circulated soon, not later than 2 weeks after meeting) • Post minutes for other employees • Report status of recommendations • Assume chairperson ’s duties, if required WORKERS REPS appointed by employer • Report unsafe conditions and practices • Attend all safety meetings • Report all accidents or near misses • Review injury accidents, illnesses and death investigations • Contribute ideas and suggestions for improvement of safety • Work safely • Influence others to work safely • Make or assist in inspections # Employer shall not penalize a member of the committee in any manner for being absent from his normal duties at work while carrying out the functions of the committee MANAGEMENT REPS selected by workers or appointed by employer • Allocating adequate resources (financial, assets & human training) for the best possible functioning of the OSH programmed. • Building up a good management team or organizational representatives to support OSH development in the company. • Assigning a senior management representative to be responsible for OSH administration & agent to be in charge of any OSH occasion. Figure 2.0 Position Vs Function OSH Committee 39
PLANNING & IMPLEMENTATION Standard Operating Procedure (SOP) • A standard operating procedure (SOP) is a set of step-by-step instructions compiled by an organization to help workers carry out complex routine operations. • SOPs aim to achieve efficiency, quality output and uniformity of performance, while reducing miscommunication and failure to comply with industry regulations. Example Figure 2.6 SOP 40
Guideline development SOPs Figure 2.7 SOPs Guideline 41