PROEIGHT BATU CAVES FACTORY SAFETY AUDIT REPORT 1.0 INTRODUCTION A safety audit at Proeight Batu Caves factory was done on 12th July 2010. The audit done

covers the whole factory building. The audit started at about 245 pm and ended at about 515

pm.

2.0 OBJECTIVES The objective of this safety audit is to identify health, safety, security and environmental issues

present at the factory, verify compliance with legal requirements and recommend improvements

that can be made.

3.0 SCOPE The scope of the audit covers all health, safety, security and environment legal aspects,

code of practice and guidelines.

4.0 METHODOLOGY The inspection was conducted through a site walkthrough with employees there and inspection

is made at all the areas in the building. Observations were made and pictures were taken as

evidence. Interviews with employees there were also conducted to get as many information

available and to get their feedback regarding HSSE issues.

5.0 FINDINGS Based on the observations and interviews made during the audit, there are several issues that

need to be highlighted and require management attentions to improve the existing condition and

thus, reducing risk and provide safe working environment to the employees there. The findings

are as follows:

5.0.1 Work environment

Observation showed that storage and placement of all things still need to be improved as boxes

and stuff are placed everywhere. There is no designated area for pallet truck and trolley. In

respect to chemical fumes and particulates, lapping room, EDM room, silica carbide and carbon

room has no or inadequate exhaust fan. The fumes and particulate are strong and hazardous

for employee working inside the room.

5.0.3 Work procedures

A work procedure is available for air pressure test but there is absence of pre-start checklist

before performing the pressure test. A checklist should be developed as the test involved

pressure hazards which can cause accident if not properly checked. The checklist should

include all criteria that are required for safe operation of the test. No Hazard Identification, Risk

Assessment and Risk Control (HIRARC) have been done for every work activity done in the

factory.

5.0.2 Chemical management

Chemical management includes proper labelling of chemical container, proper storage area,

availability of chemical register and respective MSDS. Observation made shown that there is no

chemical register present but there is list of chemical MSDS available at the factory. There is

also no designated cabinet for chemical storage. Chemical Health Risk Assessment (CHRA)

has never been conducted at the factory.

5.0.4 Scheduled waste management

Scheduled waste is hazardous waste that cannot be disposed as other general waste. It must

be treated at a prescribed premise licensed by Department of Environment (DOE) before being

disposed. Notification to DOE of our scheduled waste as stated in Environmental Quality

(Scheduled Wastes) Regulation 2005 is not done yet. No segregation is made between general

waste and scheduled waste. There are no proper labelling, container and storage area as

outlined in the Regulation.

5.0.5 Personal Protective Equipments (PPE)

Reusable PPE is given to each employees and they kept it in their own locker. Reusable PPE

given are ear plug, safety spectacles and safety shoes. Disposable PPE is also provided which

is ear plug and N95 respirator. This respirator is used for carbon room and lapping room. N95 is

not suitable for lapping room as it only protect from particulate and not chemical vapour.

5.0.6 Safety Signage

Stairs leading to store on third floor also has no signage to warn about the steep stair. There is

also no signage for elevated barrier at store entrance door. No safety signage and PPE signage

at the wood cutting area.

5.0.7 Emergency response procedures

After walking through the factory and observation were made, it is found that there is no

evacuation procedures pasted at the second floor. It is unsafe condition in case of emergency.

5.0.8 Training

It is found out, after interviews were made with worker, they have been trained for fire

evacuation procedure. There is no training provided other than that.

6.0 RECOMMENDATION

6.0.1 Work environment

Housekeeping need to be done to reduce risk of slip, trip and fall. Merchandise and things that

is not for use should be dispose and things to be used to be stored properly. Lines indicating

designated area for pallet truck should be done to prevent the pallet truck placed improperly.

Occupational Safety and Health (Use and Standards Exposure of Chemicals Hazardous to

Health) Regulations 2000 suggested the installation of Local Exhaust Ventilation for chemical

hazards to reduce the concentration of vapour in a room.

6.0.2 Work procedures

A checklist will be developed with cooperation from QA/QC side. The checklist will take into

account all the safety requirements and criteria to be checked to ensure safe operation of the

test.

6.0.3 Chemical management

All chemical containers will be provided with proper chemical labelling according to

Occupational Safety and Health (Classification, Packaging and Labelling) Regulations 1997. It

will contain all the information required such as the hazards and safe handling procedures.

Chemical register will be developed and placed at the workplace along with list of each MSDS

used in the factory.

5.0.4 Scheduled waste management

Notification to DOE will be made for all of the generated scheduled waste as stated in

Environmental Quality (Scheduled Wastes) Regulation 2005. Notification to DOE will be made

using the form given in the Second Schedule of the Regulations. A monthly inventory will be

produced to keep date of schedule waste volume generated. Separate bin for general and

scheduled wastes will be provided for the factory. Label will be created and attached at the

scheduled waste container which shall contain name of company, date first generated,

telephone number and address of the company, and symbol as per Third Schedule. Proper

container and storage area should be provided for the scheduled wastes.

6.0.5 Personal Protective Equipment (PPE)

The types of respirator suitable such as P95, P99 (NIOSH classification) or FFP2 (EN149:2001)

will be looked into and buy for workers usage. The respirator should also been certified by

DOSH.

6.0.6 Safety signage

Safety signage for the stair leading to store, elevated barrier at store entrance door and wood

cutting area will be put up.

6.0.7 Emergency response procedures

Emergency evacuation procedures will be put up at strategic areas at each level and briefed to

all the employees there. Evacuation map will be put on at strategic areas at the factory which

will include emergency contact number.

6.0.8 Training

Fire drill exercise will be done periodically to ensure workers are trained in case of emergency.

Basic Occupational First Aid training will be planned and give to the employees there so that

they are well-versed during emergency. Other training necessary such as machinery safety and

PPE is in plan and will be given at appropriate time.

No Picture Findings Recommendation Person-in-charge

1 EDM room, lapping room and

silica carbide room have no

exhaust fan to captures the

fumes and channel it outside

To install exhaust fan with high

velocity or local exhaust ventilation

to remove the fumes efficiently

Management &

HSSE

7.0 SUMMARY

2

Cable and wires of computer

at machine is poorly managed

Buy and use cable zip to properly

tie all the cable together

IT Department

3

No label indicating recycle

paper container

To print and put up label indicating

recycle paper

HSSE

4

Lot of things being stored

improperly under the stairs

To clear the area of unnecessary

things

Factory

5

No designated area for pallet

truck

To draw safety lines for pallet truck

parking

Batu Caves and

HSSE

6

Metal chips tend to escape to

the floor

To put up guard or barrier to

prevent metal chips from escaping

to the ground floor

Batu Caves and

HSSE

7

No proper chemical cabinet

for storage of chemical

Buy proper fire resistance cabinet

with spill containment features for

chemical storage

HSSE

8

Inadequate labelling of

chemical container

To produce a standardized label

for all chemical container which

meet the requirement

HSSE

9

Improper container for

chemical

No label pasted at the

container

To buy proper container for

chemicals

To put chemical label for the

container

HSSE

10

Notification is not made to

DOE

Inventory has not been

done for scheduled wastes

No segregation between

general and scheduled

wastes

Inadequate label for

scheduled waste container

No appointer contractor for

scheduled wastes disposal

Notification will be made to

DOE as in legal requirements

To produce monthly inventory

for scheduled waste volume

produced

No segregation between

general and scheduled wastes

To produce label as stated in

Scheduled Wastes Regulations

2005 for all scheduled waste

types

To appoint licensed contractor

for collection and disposal of

scheduled wastes

Batu Caves and

HSSE

11 Unsuitable types of PPE for

workers usage

For particulate protection, type

of respirator should be N99

filter

For chemical vapour, type of

respirator is P95

HSSE

12

No signage to warn about the

elevated barrier

To produce signage and put it at

place

HSSE

13

No exit signage at the door To install exit signage on top of the

door

HSSE

8.0 Conclusion

After the audit was done, it is found out that a lot of HSSE issues such as scheduled waste,

chemical management, emergency response plan and trainings can be improved. Safety and

health aspect are very vital in successful business operation and must be given attention as

other critical business decision. This is to ensure safe working environment thus protecting the

safety and health of workers and the environment.