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The International Journal Of Engineering And Science (IJES)
|| Volume || 3 || Issue || 10 || Pages || 62-68 || 2014 ||
ISSN (e): 2319 – 1813 ISSN (p): 2319 – 1805
www.theijes.com The IJES Page 62
Developing Accident Avoidance Program for Occupational
Safety and Health
1Khairul Akmal Shamsuddin, 2Mohd Norzaimi Che Ani,
3Mohd Hairizal Osman
Mechanical Section, Universiti Kuala Lumpur (UniKL), Malaysian Spanish Institute (MSI)
2Manufacturing Section, Universiti Kuala Lumpur (UniKL), Malaysian Spanish Institute (MSI)
3Manufacturing Section, Universiti Kuala Lumpur (UniKL), Malaysian Spanish Institute (MSI)
--------------------------------------------------------ABSTRACT-----------------------------------------------------------
An occupational health and safety programs are effective must demonstrate effective management leadership,
worker participation, continual improvement, evaluation, integration, management review in the workplace.
Companies with good results in the box has leadership will not allow substandard result. Although
cooperation and consensus is important in gaining employee buy - in to the program, ultimately it is the
leadership and commitment from management that drives the process. The audit will assess the level of
leadership and commitment to health and safety within the organization to evaluate the program. Despite the
value to employers and workers in terms of injuries prevented and cost saved, many factories have not yet
adopted injury and illness prevention programs that workers safety. Based on the positive experience of
employers with existing programs, it believe that injury and illness prevention programs provide the
foundation for breakthrough changes in the way employers identify and control hazards, leading to
significantly improved overall workplace health and safety environments. Adoption of injury and illness
prevention program will result in both improved workers safety and workers suffering fewer injuries, illnesses
and fatalities.
KEYWORDS - Occupational Health and Safety, Injuries and Illness, Workers safety and Hazards.
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Date of Submission: 03 October 2014 Date of Publication: 20 October 2014
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I. INTRODUCTION
In today’s world, rapid economic development has not only led to significant improvements in
incomes and the quality of life, but also resulted in great increases in the number of people killed and injured at
work. An “accident” is defined as an unplanned, undesired event that results in personal injury or property
damage. Accident in workplace often happen as a result of neglecting the precaution measures in the
competitive market where advanced technologies, intensive exploitation of resources, the increasing of natural
and technical threats which resulting in lower economic growth rate (M. Spilka, 2010). In Malaysia,
workplace-related accidents have continued to rise according to report of Department of Occupational Safety
and Health (DOSH). Sectors that involved were manufacturing; mining and quarrying; construction;
agriculture; forestry and fisheries; facilities; transportation; storage and communication; wholesaling and
retailing; hotels and restaurants; finance, insurance, real estate and services; and civil service.
In 2012, a total 2,824 of accidents were recorded by DOSH, 179 cases were fatal, 205 cases are
permanent disability and 2,440 cases are without permanent disability. The numbers of accidents increased by
405 cases compared to 2,419 in year 2011. Accidents in the workplace happen for a number of reasons. The
results of a workplace accident can be minimal or tragic, causing minor injury, damage to equipment or even
in some cases, major injury or death. According to Occupational Accidents Statistics 2012, the percentages of
accidents in manufacturing sector are always higher than other sectors. The manufacturing sector made up the
highest number of workplace accidents at 60.91% with 1720 cases, comprising 40 fatal cases, 147 cases
permanent disability and without 1533 cases permanent disability.
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This paper aims to design the accident avoidance program to improve the safety and health in
manufacturing environment. Section 2 describes the methodology used to design the accident program, Section
3 presents the case study and the results conducted in the case study company, Section 4 compares the results
from Section 3, Section 5 discussions the results, and Section 6 concludes the paper.
II.FRAMEWORK OF THE ACCIDENT AVOIDANCE PROGRAM
The framework model of the accident avoidance program shows in Figure 1. Stage 1 is data collection
about the industrial accident in case study industry. Identify the type of industry and type of accident and
injury. Stage 2 is analyzing the data and defines the possible root cause of the accident. Stage 3 is proposing
the possible counter measures to avoid occurring accident in the future and stage 4 is develop the accident
avoidance program in case study industry.
Figure 1: Methodology framework
III. CASE STUDY AND DATA ANALYSIS
A worker at ABC manufacturing company was welding on a sealed and empty metal drum that had
previously contained acetone. The welding instrument burned through the surface of the thin metal, igniting
the flammable acetone vapour inside the drum. The drum exploded and struck the worker, throwing him
across the room onto a concrete floor. The worker sustained fatal injury.
Root cause analysis (RCA) is a systematic technique that focuses on finding the real cause of a problem.
To determine the causal factor of an accident, Fishbone Diagram had applied in this fatal case. Hazardous
conditions may exist in any of the following categories as a Figure 2.
Figure 2: Root cause analysis (RCA)
A. Man or People
Most accidents in the workplace result from human behaviors which is worker, supervisor or manager.
It might occurs if the worker horseplay during carry their task. While, carelessness and laziness of worker is
another cause of accidents due to they not performed drum cleaning which is contain flammable acetone.
Others factor might supervisor or manager lack of safety leadership, they not provide well training on chemical
handling and ignore the hazard during pass down and practices. Besides that, miscommunication issue might
happen during pass down or training. Worker might carry their task based on their understanding.
Additionally, company hired unqualified or poor skilled worker due to cost saving on wages.
Stage 1:
select
case
study
Stage 2:
Identify
possible
root
causes
Stage 3:
Proposes
possible
counter
measures
Stage 4:
Develop
accident
avoidance
program
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B. Method
Method also is one of important factor that have directly caused or contributed in some way to the
workplace accident. Workers did not follow the actual working procedure and improper technique or method
can caused accidents at work. Most accidents in the workplace result from unsafe work practices which is the
worker ignore the safety rules during carrying the task. Others reasons might due to lack of elementary
knowledge in working method and chemical handle because of they are not undergo a complete training and
instruction session.
C. Management
Management of an organization plays a very importance role on the safety working environment.
Management system weaknesses is a major root cause of workplace accident happened. It is included missing
or inadequate safety policies or rules, training program not in place, safety policies or rules are not being
enforced, safety training is not being conducted, adequate supervision is not conducted and management might
lack of safety leadership. For instance, management should provide safety training to new hire employee such
as method of using PPE, on job training, and also safety precaution training. Poor leadership and management
in the workplace can cause numerous negative consequences for employees
D. Material
Hazardous material found in this accident are flammable chemical (Acetone), empty metal drum that
contained acetone and welding instrument. It was suspected that the empty metals drum no segregate and
without proper label for identification cause that worker welding on the drum without perform cleaning. Apart
from that, the worker might lack of elementary knowledge in chemical properties due to there is no MSDS for
the acetone.
E. Safety
In safety point of view, poor 5S or housekeeping and defective Personal Protect Equipment (PPE) might
increase the risks of injury. Besides that, worker who lack of safety awareness have always ignore hazards and
failing to comply procedure during carrying their task.
IV. METHOD TO AVOID RECURRENCE ACCIDENT
The best way to avoid accidents in the workplace is to be proactive with prevention. An ounce of
prevention is worth a pound of cure. Preventing accidents and injuries within the workplace is done by
controlling hazards and mitigating risks. One of the challenges is identifying the hazards and risks before it
causes an injury or other serious incident. There are many ways to prevent accidents but in implementing these
methods, an organization needs to be consistent and communicate their expectations clearly. To successfully
avoid accidents in the workplace, review the following list of safety suggestions.
A. Put Formal Safety Policies and Procedures in Place
Create a company handbook that lists out the steps that must take place in order to prevent accidents in the
work place. Include procedure and instructions such as welding work instruction, chemical handling method,
and hazardous materials identification to alert employers and workers; raise their safety awareness to the
dangers of the product.
B. Implement 5S or Good Housekeeping
A well maintained work area sets a standard for all. Poor housekeeping creates all types of hazards and sets
the stage for accidents. Good housekeeping encourages pride and a safe environment. Keep the working
environment clean and tidy, with floors and access routes kept clear of obstacles.
C. Metal Drum Allocation Area and Segregation
All metal drum must proper allocation and segregation for before cleaning and after cleaning. Metal drum
that contained acetone must segregate properly to avoid mixed with metal drum after cleaning. For instance,
drum before cleaning must place in area with RED color layout and every drum must label with red color
sticker as status indicator. On the others hand, drum after cleaning must place in GREEN layout with green
sticker identification. So that, workers can easily to identify the drum condition and can proceed to the next
step. This action can avoid recurrence of accident on worker who welding on drum without performed cleaning
that may contain acetone.
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Figure 3: Proper Allocation Area
D. Labels and Material Safety Data Sheets (MSDS)
Labels must be placed on all containers of hazardous materials to alert employers and workers to the dangers
of the product and basic safety precautions. For instance, every metal drum can identified with color sticker to
segregate drum before cleaning and drum after cleaning. MSDS must be prepared for all hazardous products.
These data sheets provide more detailed information about the product than can be put on a label. MSDS
should keep at workplace for all workers to refer when they are needed.
E. Workplace Safety Inspection
Supervisors should conduct periodic safety inspections to identify unsafe work practices. For instance, they
should be on the lookout for workers who are not wearing appropriate clothing or protective equipment during
doing their task; workers performed drum cleaning with unsafe manner; failure to follow established safety
policies or warning signs; employees using unsafe welding techniques; unsafe use of equipment and other
safety hazards. Supervisors should inspect both indoor and outdoor work areas to avoid overlooking unsafe
practices. Once hazards have been identified, managers and employees should work together to eliminate or
mitigate them.
F. Worker Education and Training
Employees need to stay alert and aware at all times to avoid accidents, while managers need to know the
most common causes for workplace accidents and be able to spot the risk factors early for prevention. So
management should provide worker education programs on the hazards of chemicals in the workplace and
training in understanding and using the OSHA information. Improve knowledge of chemical handling of
worker. The ultimate goal of OSHA is to create a safer workplace by providing workers with the knowledge
and tools to enable them to understand the hazards and to work safely.
G. Personnel Protective Equipment (PPE)
Management must provide the training on using appropriate protection clothing and equipment to ensure
their worker safety. Personnel Protective Equipment (PPE) greatly reduces the risk of injury and minimizes the
effects of toxins. Protective clothing and equipment must be worn during all welding operations. Every worker
who performed welding process must wear PPE which are clear face shield, helmet with respirator, leather
apron, sleeves, leg apron, coat, glove and cape and rib to protect welders from injury.
V. ACCIDENT PREVENTION PROGRAM
Workplace accidents prevention programs are proactive processes that can substantially reduce the
number and severity of workplace injuries and illnesses and can alleviate the associated financial burdens on
workplaces. These systematic programs allow employers and workers to collaborate on an ongoing basis to find
and fix workplace hazards before workers are hurt or become ill. This kind of programs can provide the
foundation for breakthrough changes in the way employers and their workers identify and control hazards,
leading to a significantly improved workplace health and safety environment. Adoption of a workplace
accident prevention program will result in workers suffering fewer injuries, illnesses and fatalities. In addition,
employers will improve their compliance with existing standards and experience the financial benefits of a
safer and healthier workplace. There are few steps to develop a good accident prevention program, it is include
develop management leadership and commitment, worker participation, hazard identification and assessment,
hazard prevention and control, education and training and program evaluation and improvement.
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A. Step 1-Management Leadership and Commitment
Management leadership and commitment is crucial to the success of the workplace accident program.
Management must not only establish the program and communicate it to everyone in the organization, but also
provide the resources to improve safety and health throughout the entire organization. This includes providing
employees and supervisors with the authority to identify and correct hazards, the budget to purchase new
equipment or make repairs, the training necessary to work safely and to recognize hazards, and the systems to
get repairs made, materials ordered and other improvements accomplished. Management also establishes the
importance of the accident prevention program, both by the priority they give workplace safety and health
issues and by the example they set by initiating safety and health improvements, correcting hazards, enforcing
safety rules, rewarding excellent performance in safety and health, and by following all safety rules.
B. Step 2-Worker Participation
Worker participation is a fundamental element of workplace accident programs, makes an important
contribution to an employer’s bottom line. When workers are encouraged to offer their ideas and they see their
contributions being taken seriously, they tend to be more satisfied and more productive (Huang et al.,
2006).Engaging employees in dialogue with management and each other about safety and health can lead to
improved relationships and better overall communication, along with reduced injury rates. Improved employee
morale and satisfaction translates to greater loyalty, lower absenteeism and higher productivity. For instance,
management can involve all employees in policy making on safety and health issues while manager consult
with workers in developing and implementing the program and involve them in updating and evaluating the
program. Some more include workers in workplace inspections and incident investigations. Besides that,
management must always encourage workers to report concerns, such as hazards, injuries, illnesses and near
misses. Additionally, protect the rights of workers who participate in the program also is responsibility of
management.
C. Step 3-Hazard Identification and Assessment
Identify, assess and document workplace hazards by soliciting input from workers, inspecting the
workplace and reviewing available information on hazards. Then perform investigate injuries and illnesses to
identify hazards that may have caused them. Another importance step is about the methods of organization
plans to use to identify, analyze and control workplace hazards. This includes hazards that currently exist in
the workplace and those that may occur due to future changes, such as the introduction of new equipment,
processes or materials, or the revision of existing procedures. There are several methods organizations can use
to identify hazards. Inspection of work areas and audits of safety programs are tools that can be used to identify
problems and hazards before these conditions result in accidents or injuries. Audits also help to identify the
effectiveness of safety program management can be used as a guide to assure regulatory compliance and a safe
workplace. Some rely solely on walk around inspections by first-line supervisors, management or safety
committees, others go through formal hazard analyses of different parts of the operation and some use a
combination of methods. Regardless of the methods used, the best hazard identification methods combine
expert opinion about safety and health hazards with input from either a cross-disciplinary team or at least one
employee who works directly with the process or equipment in question. At least some of the individuals
involved in hazard identification should be trained in hazard recognition. Inspections should be done on a
regular basis to identify both newly developed hazards and those previously missed. Employers should also
consider the value of periodic industrial hygiene monitoring and sampling for agents such as hazardous
substances, noise and heat. For instance, one of the more common tools used for hazard identification are
checklists. Another method often used to identify workplace hazards is job hazard analysis (JHA), also known
as job safety analysis. Job hazard analysis is a step-by-step method of identifying the hazards associated with a
particular task or job. It is important to involve the employee who normally performs the job, in the
development of the JHA.
D. Step 4-Hazard Prevention and Control
Management should establish and implement a plan to prioritize and control hazards identified in the
workplace and provide interim controls to protect workers from any hazards that cannot be controlled
immediately. Then verify that all control measures are implemented and are effective. For instance,
management must maintain equipment and tools regularly and thoroughly. Besides that, ensure that employees
know how to use and maintain personal protective equipment (PPE) and train employees in proper procedures
for handling specific situations
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E. Step 5-ducation and Training
An employer is also obligated to provide “to employees, in appropriate languages, the information,
instruction, training and supervision necessary to enable them to perform their work in a manner that is safe
and without risk to their health. For instance, provide education and training to workers in a language and
vocabulary they can understand to ensure that they know about procedures for reporting injuries, illnesses and
safety and health concerns, method on how to recognize hazards, correct ways to eliminate, control or reduce
hazards and management must conduct refresher education and training programs periodically to raise their
awareness. Establish appropriate education and training programs for staff, which may include a structured
training regime for employees, encompassing on job training, refresher training and OSH Consultation
training.
F. Step 6-Program Evaluation and Improvement
Lastly, management should conduct a periodic review at least annually of the program to determine if it
has been implemented as designed and is making progress towards achieving its goals. Program review is
vital, because it serves as a check to see if the organization is making progress toward its goal of creating a
safer, healthier workplace for all employees. The second reason for conducting a review or audit of the
workplace safety and health program is to determine whether the procedures used in the facility are consistent
with those described in the program and if they are effective. For example, if the audit shows there are injuries
and illnesses occurring from hazards that have not been identified or controlled through the methods described
in the safety and health program, the auditor needs to determine if the methods are being used in the facility
correctly and as described in the program. If the methods are not being used or are used incorrectly, the auditor
needs to determine what barriers are present that prevent the correct application of the methods. If the hazard
identification and control techniques are being applied correctly, then the organization needs to further review
the techniques and, perhaps, modify them or adopt new ones.
VI. CONCLUSION
As a conclusion, workplace accidents have great increases in the number of people killed and injured at
work while the manufacturing sector made up the highest number of workplace accidents. Most everyone
would agree that an accident is unplanned and unwanted. An accident might causes property damage, or
personal injury, minor or serious and occasionally results in a fatality. Hazardous conditions may exist in man
or people, method, management, material and safety. To seek to minimize the pain and suffering, equipment
damage, loss of morale. Root cause analysis is needed to determine the causal factor. The best way to avoid
accidents in the workplace is to be proactive with prevention. An ounce of prevention is worth a pound of cure.
Workplace accidents prevention programs are an effective tool for reducing occupational injuries, illnesses and
fatalities. There are few steps to develop a good accident prevention program, it is include develop
management leadership and commitment, worker participation, hazard identification and assessment, hazard
prevention and control, education and training and program evaluation and improvement. Preventing accidents
and injuries within the workplace is done by controlling hazards and mitigating risks. One of the challenges is
identifying the hazards and risks before it causes an injury or other serious incident. Preventing accidents and
injuries within the workplace is done by controlling hazards and mitigating risks. One of the challenges is
identifying the hazards and risks before it causes an injury or other serious incident. If an accident does occur,
conducting a thorough analysis of the causes will help prevent future accidents from occurring. Additionally,
safety precaution and management responsibilities influence the safety climate. It is important for employer,
employee and also government to co-operate hand in hand to ensure a minimum danger risk level at the
workplace. Government need to enforce the law of Safety and Health to make sure all the industries follow the
guidelines of safe work culture. Time by time, government also need to carry out some campaigns or
workshops to increase people awareness on safe work culture and the necessary to follow the rules and
regulations. Employees need to stay alert and aware at all times to avoid accidents, while managers need to
know the most common causes for workplace accidents and be able to spot the risk factors early for prevention.
Developing Accident Avoidance Program…
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APPENDIX
Figure 4: Occupational Accidents Statistic 2011
Figure 5: Occupational Accidents Statistic 2012
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