MEMI 2803

ENGINEERING & ENVIRONMENTAL SAFETY

PROJECT TITLE

ACCIDENT OF MECHANICAL & PHYSICAL HAZARD

AT INDUSTRIAL

NO TEAM MEMBERS MATRIX NO

1 HAMZATUL HANIM HUSIN MEM221035
2 R GOBAL S RAJENDRAN MEM211030
3 VIKNESVARAN KANDASAMY MEM221021
4 KEERTHI MEM221003

LECTURER

IR. TS. DR. NOR HASRUL BIN NGADIMAN

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 TABLE OF CONTENTS

NO DESCRIPTION PAGES

Chapter 1: Introduction 3
1.1 Introduction 3
1 1.2 Background of Study 4
1.3 Problem Statement 4
Chapter 2: Literature Review 5
2.1 Assessment of Chemical Safety Awareness Among University 5
Laboratory Workers
2.2 Chemical risk and safety awareness, perception, and practices among 5
2 research laboratories workers in Italy
2.3 Accident rate manufacturing plant: A case study at the pulp and paper 6
industry in east coast Malaysia
2.4 Analysis of Workplace Accidents in Automotive Repair Workshops in 6
Spain
2.5 Description of Work Instructions as part of the Mechanical Hazard Risk 7
Control in a Construction Company
2.6 A Study on Potential Physical Hazards at Construction Sites 7
Chapter 3 : Methodology & Background 9
3.1 Unsafe act and condition of the case study 9
3 3.2 Type of hazard 11
3.3 Tool & Method 12
3.4 Implications to safety, efficiency, comfort and environment. 13
Chapter 4 : Discussion & Results 14
4 4.1 Suggestions to improve the unsafe condition of the case study 14
4.2 Safety and health organisations at workplace 14
4.3 Laws of Malaysia ( Dangerous part of machinery ) 16
5 Chapter 5 : Conclusion 18
6 References 21

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 CHAPTER 1
INTRODUCTION

1.1. Introduction

Safety is an important aspect of life today and everyone needs protection when it comes
to their safety and physical health. By securing the right to protect their physical safety
and health, people can live their lives optimally. The protection of workers' rights is done
by implementing occupational health and safety efforts to realize optimal work
productivity. This is in line with studies by Nur and Oktafa (2017) and Samahati (2020)
which state that occupational safety and health positively affect employee productivity. A
study by Wahyuni, Suyadi and Hartanto (2018) states that the percentage of occupational
safety and health influence on employee productivity is 67.9%.

Occupational safety and health in the workplace are important because every workplace
has potential hazards. Hazardous sources in the workplace can cause occupational
accidents and occupational diseases. For example, the use of sophisticated work
equipment affects the likelihood of work accidents and work-related illnesses (Agustina
and Mulyono, 2018).

Based on data from the Social Security Employment Institution, the rate of work
accidents in Indonesia is still high. It was recorded that 123,040 work accidents occurred
in 2017 (Social Security Employment Institution, 2017). Furthermore, according to data
from the Ministry of Public Works and Public Housing in 2017, the construction sector
contributes to the largest number of accident cases in Indonesia with an average of
around 32% of the total each year (Ministry of Public Works and Public Housing, 2018).
Looking at the average number of accidents, it can be considered that the construction
sector is an occupation with a high rate of potential danger.

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1.2. Background of Study

The semiconductor industry is one of the important industries that contribute to increase
in GDP (Gross Domestic Product) in our country's economy. On top year, more
mechanical & electronic projects have been done to support development and
improvement human population. However, in the semiconductor industry, accidents are
unpredictable can happen at any time during the construction period that can put the
production workers live in danger. Production manufacturing has the most employment
frequency injuries compared to other sectors.

Poor safety management and failure to control risks during production activities may
result in accidents or injuries among workers. For that therefore, effective safety
management is essential to avoid accidents and deaths, and besides that safety also
contributes to profit because it saves high direct costs such as medical costs and indirect
costs such as liability claims from injured workers. Therefore, to move the semiconductor
industry closer to the goal of zero accidents are important to improve the efficiency of
safety management in production site.

1.3. Problem Statement

The semiconductor industry is characterized by constant change, bombardment varying

technologies, poor working conditions and engagement and the need for coordination of
different interdependent trades and operations. Recently, an incident was encounter by
safety team. There was a machine start to run after tacking the dry film and hot roller
started to rotate. After the alignment setting, based on the procedure, technician need to
clean the hot rollers. She took the Bemcot and IPA to clean the hot roller A which near to
hot roller CD. During the cleaning Hot Roller A, the jumpsuit suddenly got pulled in
between Hot Roller CD. She tried to take off (pull) the jumpsuit (hand area) after 5
seconds her right hand touch the hot rollers, she cannot stop the machine manually. So,
she pressed the stop button and press hot roller "up/down” button to put down hot roller.
She called for help but teammate came only after she took off her hand as they are at
their own machine.

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 CHAPTER 2
LITERATURE REVIEW

Occupational safety and health in the workplace are important due to each workplace had
potential hazard. Healthy and safe workplace is important to ensure employee well-being
was taken care. Healthy and safe workplace able to reduce injury and accident occur in
an organization. By having a healthy and safe working environment, it also able to
provide confident to employee to continue work at the organization.

2.1. Assessment of Chemical Safety Awareness Among University

Laboratory Workers

Zaip et al. (2021) had conducted assessment among university laboratory workers which
include medical laboratory technologists, science officer and assistant science officer to
access their awareness on chemical safety. In this study, cross sectional study design was
adopted and questionnaire had been distributed to 151 participants. From the assessment
it was found that the laboratory worker in university had a moderate level of chemical
safety awareness, there was no significant differences between the three schools’
knowledge and awareness on chemical safety. However, significant correlation was
found among the worker knowledge and awareness at each school. Therefore, it was
suggested training on personal protective equipment (PPE) should be given regularly to
increase their level of awareness, and cooperation between laboratory worker and
management was required to improve current situation.

2.2. Chemical risk and Safety Awareness, Perception and Practices Among
Research Laboratory Workers in Italy

In addition, Papadopoli et al. (2020) also had conducted to assess research laboratory
workers awareness and perception on chemical hazard, investigate guideline on handling
chemical compound safely, and analyze the effect of several factors on the outcome of

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 interest. In this study, survey had been distributed to 237 participants in which it consists
of questions regard to knowledge, attitudes and behavior related to chemical hazard.
Besides, safety data sheet (SDS) had been collected and reviewed. The result shows that
more than 90 types of hazardous chemical were used by the workers and among them
54.4% of worker stated that they felt exposed to chemical risks. Thus, the finding shows
that there was significant gap between knowledge and scarce preparedness in following
safety processes in chemical compounds. Therefore, the study suggested continuous
training on chemical safety need to be given to workers and management to increase their
awareness and training on first aid should be given as an knowledge to workers to handle
emergency situation.

2.3. Accident Rate Manufacturing Plant: A Case Study at the Pulp and
Paper Industry in East Coast of Malaysia

On the other hand, study on accident rate at pulp and paper manufacturing plant had been
conducted by Salleh et al. (2017). The objective of the study was to analyse the accident
rate happen in the last 12 months in Pulp and paper industries. The study was conducted
by distributing a standardize questionnaire to 100 respondents which consists of clerical
staff, executives, technician, and managers in the organization. From the survey it was
found that the most common accident rate that happen was bleeding in which 17
respondents agreed to it while second largest accident happen was injury in which 16
respondents agreed to it. Therefore, the study suggested that continuous awareness should
be given to all level of employee in the organization to heighten their awareness. This is
due to the bleeding and injury case that happen was due to worker negligent, and not
have safety operating procedure for engine failure.

2.4. Analysis of Workplace Accidents in Automotive Repair Workshops in

Spain

Lopez-Arquillos & Rubin-Romero (2016) had conducted study on workplace accidents in

automotive repair workshops in Spain through analyse the effects of the factors involved
with various types of injury caused by occupational accidents. In this study, 89954
industry accidents had been collected throughout 2003 till 2008 as sample. From the

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 study it was found that company that have small number of employees have more
tendency to involve in injury. This is due to they are more focusing on different type of
issue and health and safety issue won’t be their priority to manage on time. Secondly, the
study found that female employee is less likely to involve in occupational injury such as
burns but they are more likely suffer from sprain. Last but not least, the study found that
foreign employees are more likely to suffer from occupational accidents such as internal
injuries. Therefore, the study suggest that safety and health training should be given to
employees based on their work nature, through this working condition will improve and
workers will have more awareness.

2.5. Description of Work Instructions as part of the Mechanical Hazard

Risk Control in a Construction Company

Meanwhile, Gitawangi and Wahyudiono (2022) had conducted study at construction

company to control mechanical hazard which contribute high accidents rate at Indonesia
factory. In this study descriptive study was applied whereby work instruction had been
developed, review and given to workers for each stage of work to control the risk of
mechanical hazard. From the study mechanical hazard was found exists in production
process of box piles which involved being hit by mold/ product due to broken sling, PC
strands breaking during stressing, PC strand punctured limbs, and the pile of products
collapsing. Thus, four methods had been used for each issue to control the mechanical
hazard. As a result, it was found that existing of work instruction documents able to
reduce mechanical hazard in which work instruction serve as a guideline for workers to
perform work based on the specific explanation at each stage.

2.6. A Study on Potential Physical Hazards at Construction Sites

Moreover, Salim et al. (2017) had conducted study on identifying potential physical
hazard at construction sites in Malaysia company due to accidents rate at construction
firms was high compared to other industry at Malaysia. 3 steps had been used in this
study to identify the hazard, firstly was identifying the hazard, secondly was assessing the
risk, and thirdly was controlling the risk. A standardize checklists had been used in this
study to identify the hazard and interviewing construction sites worker had been

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performed. From the study 14 types of hard was determine in construction sites, which
include wood carpenter, bar bender, excavation work, boring rig, hacking and drill, crane
work, roof work, bricks installation, scaffolding, electric welding, general activity,
mechanical lifting, concreating, and electrical equipment usage. Thus, from the study it
was found that in construction sites protective clothing, manual handling and roof work
was the most common hazard occurred.

In a nutshell, workplace hazard was existing in all working environment. Proper

guideline should be given to workers in performing their task, and refresher training
should be given to employees to ensure they are aware of the hazard and know whom to
report when they found the hazard.

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 CHAPTER 3
METHODOLOGY & BACKGROUD

3.1. Unsafe Act and Condition of the Case Study

Case study occurred at ABC Manufacturing which located at Pasir Gudang, Johor Bahru,
Malaysia. ABC Manufacturing is a global leading lead frame manufacturer offering
comprehensive lead frame products & material solutions to the semiconductor packaging
industry. The headquarters is in Hong Kong and started operation in year 1980. ABC
Manufacturing have two manufacturing centres in China and Malaysia respectively, and
also overseas sales offices to support worldwide customers

Figure 1: ABC Manufacturing and their product

Incident reported was happened during day shift of 3rd April 2022 at Lamination
Production Line in ABC Manufacturing. Lamination is early-stage process of lead frame
production. It is where the copper metal will be laminate with a layer of dryfilm by using
high temperature roller machine. Lead frame process flow as below:

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 Figure 2: Lead frame process flow

The technician started her worked on 7am. She operated both machines RLam 5 and
RLam 9 on that day. After she had done production for second lot at RLam 9, she did the
preventive maintenance (PM) before setup for the next lot (affected lots).

The Lamination Machine begins the operation mode after tacking the dry film and hot
roller start to rotating. The tacking will perform automatically once the system sense the
coil. Based on the procedure, after each of alligment technician need to clean the hot
rollers from any foreign materials, dust and particle stick on the roller. Hot rollers
temperature range during operation is between 100-120°C, depend on dryfilm type. As
per normal practice, she took the Bemcot and IPA to clean the hot rollers while the roller
in operation mode. The Hot Roller AB location is near to Hot Roller CD as shown in
below figure.

Figure 3: Hot rollers

She stand between both set of hot rollers at started the cleaning process. During cleaning
the Hot Roller A, due the limited space between Hot Roller AB & CD her jumpsuit

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 accidentally slip in between hot roller CD. She not able to pull off the jumpsuit (hand
area), after 5 seconds her right hand had been pull by the rotating roller CD and causing
her hand touch the hot rollers. She cannot stop the machine manually. Therefore, she
press hot roller “up/down” button to put down hot roller. She shout for help but teamate
come after she take off her hand as they at their own machine.

3.2. Types of Hazard

Almost all machine used in the industrial field may cause hazard. In this case study,
focusing on physical hazard which cause by unsafe act during handling high temperature
rotating rollers at the Lamination Machine. Physical hazard is a hazard that may cause
physical injury. Moving or rotating rollers are very risky to work with, all rotating objects
are potential hazard points which need safety attention.

Rotation is defining as circular motion around an axis or center such as rotating rollers,
collars, couplings, cams, clutches, flywheels, shaft ends, and spindles that may grip
clothing or otherwise force a body part into a dangerous location. Rotating rollers may
cause injury if safety precautions are neglected. Example of hazard due to rotating rollers
are drawing in, crushing, tearing out, severing and impact. Nip point is important to look
into when working with rotating rollers. When the parts rotating at different direction,
points where the parts may be in contact producing nip point. Stock fed between the
rollers may also produces nip points. This danger is common on machines with
intermeshing gears, rolling mills, and rollers.

Figure 4: Roller mechanism

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 A safe work space and appropriate trainings are vital to provide to workers for preventing
injuries due to the roller. For this case study due to the unsafe act during cleaning the
moving hot rollers had caused the technician experienced third stage hand burn.

Figure 5: Third stage hand burn

3.3 Tool & Method

Five Why Analysis Tool is used to identify the root cause of the incident. It is an
effective tool for incident investigation where safety team can deep dive into the problem
and finding the root cause by answering the five why questions. Five Why Analysis was
conducted as below. From this activity, the root cause was identified as no proper
cleaning tool provided to the technician for cleaning the hot rollers.

Table 1: Why-why analysis

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3.4 Implications to Safety, Efficiency, Comfort and Environment

A safe work environment is important and essential for both employees and employers.
Safer the work environment, the more productive it is. Productive employees can produce
more output, reduce rejection rate and operational costs.

Better safety will also give better health among employees. Healthier employees do tasks
more efficiently, reduces in absenteeism rates, and more focused to complete their job.

When working in a safe working environment, few accidents will occur. This results in
less downtime for incidents investigations and reduces costs for compensation. This also
reduces the time needed for employees to heal from injuries and will be less occurrence
of manpower shortage due to accidents at workplace.

Damage to industrial machines and equipment creates costs for repair and replacement.
Avoiding workplace injuries and damage to industrial equipment will causing fewer
expenses and increase profit of the company.

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 CHAPTER 4
DISCUSSIONS

4.1. Suggestions to Improve Unsafe Conditions at Workplace

According to J. N. Sorensen (2002), poor safety practices is an outcome of poor

understanding and followed by a poor personnel attitude towards the safety requirements.
In the context of the above case study, it was imperative for the employee to possess
adequate awareness on her actions that might lead to accidents & injury. Safety
awareness refers to continuous learnings given in the form of information and skills, that
is attained through practise or education; such an understanding can foster a positive
attitude and behaviour towards occupational health and safety and, as a result, potentially
reduce hazards in the workplace (Shea, et al., 2016).

Good workplace safety efforts focus on limiting factors that could cause accidents, harm
or injury to employee or workers, by integrating beneficial program into their safety
culture such as having safety policies, precautionary procedures, behavioural monitoring,
personnel training which was meant to reduce the risk and cut down on dangerous
incidents that might occur at workplace. Keeping site wide safety program not only help
in reducing accidents and injuries that will affects workers, it also helps in cutting down
on loss on manhour and improve productivity.

4.2. Safety and health organisations at workplace

In reference to Occupational Safety and Health 1994 (OSHA), there are 3 main
subsections need to be highlighted for improvement wise:

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4.2.1. Safety and Health Officer

According to OSHA, the safety and health officer shall only be employed to ensure
that the provisions of this Act and any regulations issued thereunder are duly
observed at the workplace and to promote safe work practices there. The safety and
health officer must meet the requirements or have completed the training that the
minister may occasionally specify by announcement in the Gazette. An occupier
who violates this section's OSHA requirements is guilty of an offense and, upon
conviction, subject to a fine of up to 5,000 Ringgit, a period of imprisonment of up
to six months, or both.

4.2.2. Establishment of Safety and Health Committee at Workplace

According to OSHA section 30 every employer must set up a safety and health
committee at the workplace in these following situations:

a) At the location of employment, there are at least forty people employed.

b) The deployment of such committees at work directed by the Director General.

When establishing and maintaining arrangements that will enable employer and his
employees to effectively collaborate in promoting awareness and enhancing
measures to ensure the safety and health of the employees at the place of work,
every employer is required to seek consultation from the safety and health
committee.

4.2.3. Functions of Safety and Health Committee

The responsibilities of safety and health committee are as follows:

a) Shall evaluate the measures taken to protect employees' health and safety at the
workplace.

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 b) Investigate any problem at the workplace:
i. which, in the opinion of a committee member or an employee, is unsafe or
poses a health threat.
ii. which has been brought to the employer's attention.

4.3. Laws of Malaysia (Dangerous part of machinery) Factories and

Machinery Act 1967

Every dangerous component of any machinery must be securely fenced unless it is

situated or built in a way that makes it equally safe for everyone using, visiting, or
working on the property.

The provisions of this section shall be deemed to have been met if a device is provided
that automatically prevents the operator from coming into contact with the part, provided
that the safety of a dangerous part of any machinery cannot be secured by means of a
fixed guard due to the nature of the operation.

Figure 6: Point of Operation Devices

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 Figure above illustrates the pullback and restrain devices which is suitable for this case
study hazards. Picture A method is operator’s hand will be automatically pulled if the
operator leaves at the area exposed to these kinds of hazards. Picture B method is the
operator unable to reach the hazardous area due to the press brake. The operator is
required to use hand tool to reach the danger area.

The table below describes some improvement suggestions to improve any unsafe
conditions at workplace as described in the above case study:

Table 2: Details of improvement suggestions

Unsafe
Type of Proposed Hierarchy of
S/No. condition/Unsafe Current system
hazard improvement controls
Act
Current procedure
is to perform
 To revise existing
manual cleaning by
procedure and
wiping the rollers
 Perform discontinue manual
using Bemcot &
manual machine cleaning
IPA while machine
machine while machine in
in operation.
cleaning operation and only
 There is also
while perform manual
limited space  Substitution
machine in cleaning when
01 Physical available between  Engineering
operation. machine at rest (not
both Hot Roller AB controls
 Space in operation).
and Hot Roller CD
constraint for  Proposed to install
for the operator to
the operator blower at one end of
perform manual
to perform the roller to blow
cleaning. As a
cleaning. away dust and
result, her
particles after every
cleanroom jumpsuit
lamination process.
got pulled into the
roller.
No wearing To provide heat
Operator do not wear
appropriate PPE protective gloves for
heat protective gloves
02 while handling Physical operators while PPE
while performing the
machine with hot operating machine with
manual cleaning.
surfaces. hot surfaces.

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 CHAPTER 5
CONCLUSION

Based on case study discussion from above, it is proven to have proper safety
management in workplace. Every employee in the industry understands the importance of
workplace safety because everyone wants to work in a secure environment. All industries
must prioritize health and safety to promote the wellbeing of both employers and
employees. Although there are safety risks in every industry, management should take
the time to consider and plan the steps that need to be taken in their organization to
always keep employees as safe as possible.

The following reminders are worth taking note by employees, so that we can avoid any
accidents or injuries at workplace:

a) Being aware of your surroundings: Many employees don't worry about the
dangers in their immediate surroundings. However, it's crucial to pay attention to
your co-workers' working conditions. Mechanical problems can occur at any time
while operating machinery in the workplace. Also, working with heavy equipment
is very risky and can cause accidents. If employees need to work with chemicals,
they must be very cautious. Dangerous chemicals can burn or poison employees.
Inhaling or ingesting them can even cause death. Also, working with electronic
equipment can have risks as well. Faulty electrical equipment can electrocute
employees, causing severe problems.

b) Follow Safe Operating Procedures: Workplace procedures exist to keep

employees safe, so using every tool and machine according to their instructions is
critical. This is especially true for operations that require heavy machinery.
Shortcuts lead to injury and aren’t worth the small amount of time they might save
you. Be sure you’re always using the right tool for the job and that you’re using it
correctly. Avoid cutting corners by taking the proper safety precautions when using

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 machinery or any other tool. Cutting corners is one of the main causes of workplace
loss.
c) Wear protective safety equipment: The usage of equipment worn to minimize
exposure to hazards that cause workplace injuries is significant. Not doing so can
cause injury or even death. Employees may have to work with chemicals, machines,
electronics, and other potential work hazards. Employers must provide such
employees with personal protective equipment (P.P.E.). P.P.E. should be safely
designed, constructed, and fit comfortably. Examples of P.P.E. are gloves,
protective eyewear, clothing, earplugs, hard hats, etc.

d) Inform Your Supervisor of Unsafe Situations: It's important to keep your

supervisor informed of any risks or hazards that may exist at work. They ought to
be required by law to check on whether their employees are working in a secure
environment. In order to keep yourself and other employees safe, it’s important to
always report any hazardous situation or behavior immediately. A positive safety
culture is created when everyone works together to find a solution that prevents
unsafe conditions from occurring again in the future.

In a nutshell, a safe work environment is a feature of good companies throughout the

world, and providing safety and protection at workplace is a joint effort between both
employee and employers.

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 REFERENCES

Gitawangi, S. V., & Wahyudiono, Y. D. A. (2022). Description of Work Instructions as part of

the Mechanical Hazard Risk Control in a Construction Company. The Indonesian Journal of
Occupational Safety and Health, 11(3), 367-376.

López-Arquillos, A., & Rubio-Romero, J. C. (2016). Analysis of workplace accidents in

automotive repair workshops in Spain. Safety and health at work, 7(3), 231-236.

Abuzied, S. O. (2015). A Study on Biological Occupational Hazards in Emergency Medicine in

Hospital Universiti Sains Malaysia (Doctoral dissertation, Universiti Sains Malaysia).

Salleh, A., Mohammad, R., & Talib, A. (2017). Accident rate manufacturing plant: A case
study at the pulp and paper industry in east coast Malaysia.

Zaip, N. D. M., Samad, N. I. A., Naim, F., & Hamzah, N. A. Assessment of Chemical Safety
Awareness Among University Laboratory Workers.

Salim, S. M., I Romli, F., Besar, J., & Negin, O. A. (2017). A study on potential physical
hazards at construction sites. Journal of Mechanical Engineering (JMechE), (1), 207-222.

Shea, T., De Cieri, H., Donohue, R., Cooper, B., & Sheehan, C. (2016). Leading indicators of
occupational health and safety: An employee and workplace level validation study. Safety
Science, 85, 293-304.

Sorensen, J. N. (2022). Safety culture: A survey of the state of the art. Reliability Engineering
and System Safety, 76(2002), 189-204.

Papadopoli, R., Nobile, C. G. A., Trovato, A., Pileggi, C., & Pavia, M. (2020). Chemical risk
and safety awareness, perception, and practices among research laboratories workers in
Italy. Journal of occupational medicine and toxicology, 15(1), 1-11.

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Group 5 Team Member Job Scope:

Introduction
Gobal
Literature review
Hanim Methodology and background
Discussion and results
Viknesvaran
Conclusion
Discussion and results
Keerthi
Conclusion

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