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RECOMMENDATIONS FOR OCCUPATIONAL SAFETY AND HEALTH
STANDARDS OF MATERIAL AND HANDLING DEPARTMENT,
MAJU JAYA PTE.LTD.
Prepared for
Henry Goldings, Managing Director
Maju Jaya Pte. Ltd.
3039, Jalan Perusahaan 2
45000, Johor Bahru, Johor.
By
Jamilah Zawawi, Occupational Safety and Health Manager
Maju Jaya Pte. Ltd.
3039, Jalan Perusahaan 2
45000, Johor Bahru, Johor.
10 November 2012
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1.0 Introduction
Since 1950, the International Labour Organization (ILO) and the World Health
Organization (WHO) have shared a common definition of occupational health. It was
adopted by the Joint ILO/WHO Committee on Occupational Health at its first session in 1950
and revised at its twelfth session in 1995. The definition reads:
"Occupational health should aim at: the promotion and maintenance of the highest degree of
physical, mental and social well-being of workers in all occupations; the prevention amongst
workers of departures from health caused by their working conditions; the protection of
workers in their employment from risks resulting from factors adverse to health; the placing
and maintenance of the worker in an occupational environment adapted to his physiological
and psychological capabilities; and, to summarize, the adaptation of work to man and of each
man to his job.
"The main focus in occupational health is on three different objectives: (i) the maintenance
and promotion of workers health and working capacity; (ii) the improvement of working
environment and work to become conducive to safety and health and (iii) development of
work organizations and working cultures in a direction which supports health and safety at
work and in doing so also promotes a positive social climate and smooth operation and may
enhance productivity of the undertakings. The concept of working culture is intended in this
context to mean a reflection of the essential value systems adopted by the undertaking
concerned. Such a culture is reflected in practice in the managerial systems, personnel policy,
principles for participation, training policies and quality management of the undertaking."
Joint ILO/WHO Committee on Occupational Health.
This report looks at common hazards faced daily by workers in the Material and Handlingdepartment of our garment factory (Maju Jaya Pte.Ltd.) in Johor Bahru, Johor. The report
gives some idea about working conditions related to occupational safety and health. As a
result of the globalisation of trade, this statement shows how those workers suffered from the
Multifibre Arrangement garment and textile quota system that supplied by the two of our
clients, the US and EU until this year. Our factory produces clothes like T-shirts, jeans, and
other casual wear. The productions are distributed nationwide and we also export some of our
goods to the US and EU and across Asian countries.
http://en.wikipedia.org/wiki/International_Labour_Organizationhttp://en.wikipedia.org/wiki/World_Health_Organizationhttp://en.wikipedia.org/wiki/World_Health_Organizationhttp://en.wikipedia.org/wiki/World_Health_Organizationhttp://en.wikipedia.org/wiki/World_Health_Organizationhttp://en.wikipedia.org/wiki/International_Labour_Organization7/29/2019 Work Hazards in Offices
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2.0 Work hazards in the Maju Jaya Pte. Ltd. garment factory:
Our factory employs around 1,000 workers. These workers are allocated in different sections
of the factory to ensure the smooth running of the factory. A vast number of workers (550
pax) are working at the Material Handling Department, the largest section and also the
heart of our factory. This section is divided into several small units. They are described
below:
i) WarehouseThe warehouse is the first section of our factory. It contains all the new equipment and raw
materials to provide the different sections in the factory and another branch of the company
that produces sportswear. There are around 30 workers in the warehouse, and most of them
are men because it involves heavy work such as lifting bolts of cloth etc. from containers into
the warehouse and workers also prepare materials inside the warehouse. Common problems
for workers in the warehouse are back pain, shoulder pain, muscle pain and also chemical-
related problems such as dermatitis and other skin irritations. Apart from that, I have
observed that some of the men workers smoke in the warehouse during the recess time and
this is hazardous and can cause a major disaster if a fire started. Accidents happen often in the
warehouse because materials are stored haphazardly causing frequent falls. Inside the
warehouse there is not much space and no system at all for storing the material, so workers
just put it anywhere, causing accidents especially when fire breaks out, making it difficult to
exit easily from the room; they can die or become injured.
ii) Cutting sectionThe cutting section has around 50 workers, generally equal numbers of men and women.
Mens functions are to lift the heavy bolts of cloth onto the table for cutting by the electric
cutter, so they can have problems like back pain from lifting, and women cut their hands in
the cutter. All workers in this section are exposed to chemicals (dyes etc.) and dust; some
cloths contain dangerous chemicals. In addition, the air ventilation of this section is found out
to be poorly maintained. Furthermore, the cutting section shares space with the sewing
section so they also have problems with dust like allergies and skin irritation problems. What
I observed, the workers negligence in using the gloves, eye masks and mouth cover during
the working period.
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iii) Sewing section
Most of the 300 sewing section employees are women who work in three sewing
departments. The nature of their function means that they have to sit for long working hours,
consequently they suffer back pain, exposure to dust, puncturing by needle (which can shatterwrist, hand, and finger bones), and exposure to residual chemicals because they have close
and prolonged contact with all types of cloth. In particular there are many diseased women
because they have sit for a long time, using limited body resources related with low wages, so
it is difficult for them to work hard.
Quality Control at end of sewing production line of Maju Jaya Pte. Ltd. Photo: C.K. Tan
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iv) First quality control section (Buttoning, Quality Control, and Button hole)
In the first quality control section there are several sections combined - Buttoning, Quality
Control (QC), and Button Holing. The number of workers in those sections is around 80; they
are all women. Different hazards are related with different sections; in the buttoning section
most of the workers can easily injure their hands in the buttoning machine because the
workers here have to work very fast because they are paid by piece rate and also the line
production manager constantly demands that they hurry up so the clothes can be sent to the
washing section. In the QC some workers sit for a long time while other workers stand for a
long time - neither posture is healthy; mostly they get back pain and foot pain after working
in the factory for several years. The button hole section is almost like the buttoning section
except they use needles to finish sewing the holes so another problem for workers is broken
needles flying aroundmost dangerous when they hit an eye.
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v) Sand washing section
In this section the function of workers is very dangerous because they have to use a
pneumatic (air-powered) gun to blast the sand and wash the jeans. So there is too much dust
from the sand and cloth that gets into the body creating respiratory diseases. Workers can also
be injured by sand blasting the skin and eyes and can be very serious because the sand shot
by the very strong gun easily hits the skin and eyes. All workers in this section are exposed to
sand dust and chemicals and dust from the jeans.
vi) Washing section
In the washing section there are many different types of machine. Each machine has different
problems, such as the workers have to bend right inside the machine to insert the cloth for
washing and spin-drying; accidents are easily caused if the machine is accidentally switched
on because of inadequate safety systems. All the workers in this section are exposed to
chemicals every day, particularly bleach and detergents, but workers dont know which
chemical affects what part of health so some workers resign or are dismissed. They go back
home or work in another factory but no one has yet found out a disease that is related with the
washing section.
vii) Finishing section (QC, Ironing, Buttoning, and Packing)
In this section the workers have to work really fast because all these departments are paid by
piece rate. Working hazards of QC, buttoning, and packing are almost the same problems as
those in the warehouse (section 1) and first quality control (section 4) but the ironing section
has different working hazards - workers are regularly scalded by the very hot steam from the
ironing machine, especially when the machine breaks down or is damaged.
2.1 Highlighted common hazards in Maju Jaya Pte. Ltd.
In all seven sections workers face major problems from sitting and standing for long periods
of time, chemical exposure, dust, broken needles, and physical accidents. But there is anothermain hazard in our garment factory; it is known as the mental issue. Every factorys policy
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is to constantly earn more profit. To do this the employer frequently forces workers to do
overtime as well as making them work hard to fulfil normal production-time requirements.
Managers also curse the workers every day to make them work harder. Furthermore they are
often threatened by section managers or administrative staff to decrease salary, be dismissed,
and not allowed to work overtime, because workers need overtime to receive enough salary
for their livelihoods - the minimum wage is only MYR500, which cannot support even the
simplest decent life. Therefore workers are concerned daily about job security, which is often
more important than health and safety. That is why they have constant stress in their minds
that can even lead to serious mental disorders. At the same time as all the problems above
there is a specific hazard at the workplace for women - sexual harassment is also a threat to
the women workers every day. Sometimes, gangsters sexually harass women who work at
night or overtime into the night when they go back to the guest home.
3.0 Suggested solutions to these hazards
For the above mentioned hazards or occupational safety and health issues highlighted in the
report above, I would like to suggest a few solutions that are effective and can be taken into
serious considerations by our company to ensure the safety of all our workers and the smooth
running of this company.
3.1 Office/ Factory environment and health
The factory environment is a combination of lighting, temperature, humidity, air quality and
decoration. It can be a healthy and comfortable place to work in if the correct combinations
of these elements are maintained. Workers may experience some ill-health effect which may
be due to the factory environment (e.g. headaches, lethargy, eye, nose throat problems, stress
and etc.) and require competent investigation. To prevent such ill-health in the factory ensure
the following issues are addressed.
i) TemperatureA comfortable temperature must be maintained. Most people work comfortably at
temperature between 20 - 26 degree Celsius. Almost all factories in Malaysia use air-
conditioning system to maintain the comfortable temperature. The temperature can be
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localised. So, additional windows, skylights or glass partitions in offices should not allow
excessive temperatures during hot weather.
ii) HumidityRefers to the amount of water vapour in the air. The optimum comfort range for relative
humidity is 40-60 per cent.
Low humidity can cause dryness of the eyes, nose and throat and may also increase the frequency of
static electricity shocks.
High humidity, above 80% can be associated with fatigue and report of "stuffiness".
If relative humidity is consistently high or low call in an air-conditioning experts to conduct a
review.
iii) VentilationRefers to the movement of the air and rate of fresh air input. Air movement of less than 0.1
meters per second can lead to stuffy rooms whereas above 0.2 meters per second, draughts
can be felt. Ventilation must be adequate. For each person a minimum rate of 10 liters fresh
air per second per person for general office space or 10 liters fresh air per second for every 10
square meters of floor space is recommended. Factories should be ventilated either naturally
or artificially. For most factories, opening windows or doors will provide adequateventilation. Where mechanical ventilation or air-conditioning is provided make sure the
system is regularly checked, kept clean and well maintained to prevent a growth of legionella
bacteria or other organisms.
iv) Contaminated AirContaminants in the office can include bacteria, viruses, mould spores and dust, solvent
vapors, or chemicals generated or used in the building. Air conditioning unit that do not
provide adequate amounts of fresh air can cause high levels of carbon dioxide. Stale air due
to poor ventilation and excessive heat build-up or humidity can also contribute to air
contamination. Appropriate control measures for the reduction of air contamination include:
Effective air filtration,
Ensuring that adequate amounts of fresh air enter the building,
Maintenance of air- conditioning units including regular cleaning,
Preventing the obstruction of vent
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Locating equipment using solvents in non-airconditioned area with substantial air
movement and/ or installing local exhaust ventilation.
v) SmokingEnvironment tobacco smoke is an indoor contaminant and there is growing recognition that
non-smokers may suffer adverse health effects through inhaling tobacco smoke.
Organisations are increasingly expected to limit passive smoking risks in office in the interest
of their employees and clients. A number of employers have fulfilled their legal obligations
to provide a safe and healthy work environment by implementing no-smoking policies in
their workplaces. Procedures such as consultation, education programs and the allocation of
designated smoking areas are recommended for the development of an effective no-smoking
policy.
vi) LightingAdequate lighting must be provided. Where possible offices should have natural lighting.
When artificial lighting is used it should be sufficient so as to avoid visual fatigue and
prevent glare or reflection into the workers eyes. The basic requirement for adequate lighting
are that the work must be easy to see and the light comfortable to the eyes. Illumination is
measure in units of LUX (Lumens per square metre). Suitable light levels based on Malaysia
Standard for interior lighting (see COP for Interior Lighting) are:
General background 200 Lux
Routine Office work 400 Lux
Work with poor contrast (Proof reading) 600 Lux
Sharp differences in illumination between adjacent area should be avoided. Ideally the
surrounding area should be slightly lower in luminous background. Light should fall from the
side rather than from the front to avoid reflections on the work surfaces. Glare causes visual
discomfort and is usually caused by light sources which are too bright or inadequately
shielded. Light deteriorate with age and accumulate dirt over the surface. It is advisable to
ensure that lights are cleaned at regular intervals, at least every 6- 12 months. Fluorescent
light flicker indicates either the tube or starter needs replacing.
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3.2 Welfare facilities
Welfare facilities like eating facilities, sanitary facilities, washbasins etc. should be available.
Ensure adequate facilities for boiling water and taking meals are provided for office
employees or ensure they have reasonable access to these facilities. Provided enough toilets
for employees and keep them clean and in good order. For washing, provide running water,
soap and towels or other means of drying. The minimum toilets facilities are given in table 1
below. A wholesome supply of drinking water should also be provided. Sanitary facilities
should be kept clean and well ventilated. They must not exit into a work-room except through
the open air or intervening ventilated space. The facilities must be located as near as possible
to the office. Where there are no separate facilities provided for the public, the number of
conveniences specified above should be increased as necessary to ensure that workers can use
the facilities without undue delay. One washbasin must be provided for every 20 employees
up to 100 employees and one for every 40 employees, or part thereof, after that.
Number of people at work Number of water closets
1 to 5
6 to 25
26 to 50
51 to 75
76 to 100
1
2
3
4
5
Table 1.0
3.2.1 Cleanliness
The standard of cleanliness required will depend on the use to which the office is put. Floors
and indoor traffic routes should be cleaned at least once per week. Any waste material that
accumulates should be removed on a daily basis. Interior walls, ceiling, windows and work
surfaces should be cleaned at suitable intervals, so as to maintain an appropriate hygienestandard. Ensure contract office cleaners are given the same health and safety protection as
regular office workers.
3.2.2 Safety in Factory
Most factory accidents result from slip, trips and fall, lifting objects, punctures or cuts and
being caught in or between things. Slips are caused by slippery floors, uncleaned spillages or
gripless shoes. Trips occur over objects lying on the ground or jutting out into aisles or
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because of poorly maintained floor surfaces. Falls can be from ladders or from standing on
chairs to reach an object. Many of these accidents can be avoided by simple planning and
good housekeeping. Traffic ways and aisles should be well lit, and be kept clear of material,
equipment, rubbish and electric leads.
Floor should be level and the use of mats discouraged. Spilled liquids and anything else
dropped on the floor should be immediately picked up or cleaned.
Free standing fittings should be completely stable or secured to the wall or floor. Filing
cabinets should be placed so that they do not open in to aisles and should never be left with
cabinets drawers open. For stability load cabinets starting from the bottom and do not open
more than one drawer at a time.
Office machine and equipment should be kept in good working order. Equipment using
hand-fed process such as electric staplers and paper guillotines should be guarded and staff
trained in their proper use,
Many pieces of equipment using electricity can mean trailing cables, overloaded circuits,
broken plugs and sockets. Ensure that these dangers are seen to by qualified personnel.
3.3 Manual Handling
Manual handling is a term used to describe everyday type activities such as carrying,
stacking, pushing, pulling, rolling, sliding, lifting or lowering loads. For office workers this
can include task such as moving boxes of stores, filing, setting equipment from cupboards
and filling the photocopying machine with paper.
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A common factory hazard is the manual movement of loads leading to back injuries and pain
in hand, wrist and neck. To reduce the likelihood of these types of accidents the requirements
are:
remove the need for manual handling that could be the cause of injury,
identify those tasks where manual handling cannot be avoided and assess the risk of injury,
reduce the risk of injury by rearranging the work being done (e.g. have paper delivered to
photocopier by hand truck rather than manually carrying it from stores, reduce weight to be
lifted, etc.)
provided manual handling training to workers who need it (messengers, service attendants
etc.) and give them information on the weights being lifted and how to plan a lift.
3.4 Chemicals
Small quantities of chemical are used in the office or factory and include printing inks,
photocopier toners, cleaning chemicals and correction fluids. Ensure workers are aware of
their hazards. These hazards together with the appropriate safeguards are normally detailed in
the material safety data sheets (available from supplier). Keep these sheet up-to-date and keep
them in a location where workers can consult them easily.
3.5 Recess / Rest breaks and exercise
The key to preventing overuse injuries is to break repetitive work with non-repetitive task or
exercises and/or rest breaks. Employees need to move around and reduce the effects of
fatigue by doing different task. However rest breaks should be taken if the job requires a
sustained period of repetitive or static activity because task variation is not possible.
3.6 Legal Requirements
OCCUPATIONAL SAFETY AND HEALTH ACT 1994
The Occupational Safety and Health Act 1994 aims to secure the safety, health and welfare of
persons at work, for protecting others against risks to safety or health in connection with the
activities or persons at work. Under the Act employers, employees and the self-employed are
required to meet certain standards on safety, health and welfare. Employers must ensure the
safety, health and welfare of their employees. To comply, employers must:
Provide or maintain equipment and systems of work that are safe and without risks to
health.
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Ensure that equipment and substances are used, stored and transported safely and without
risks to health.
Provide information, instruction, training and supervision that ensure the safety and health
of employees.
Maintain their workplace in a safe condition including entrances and exits.
Employers must also ensure the safety and health of visitors to the work places.
Employees must:
Cooperate with their employers in their efforts to maintain the required level of safety and
health.
Take reasonable care of the safety and health of one-self and others.
Manufactures and suppliers of equipment and substances must:
Ensure that products are safe and not a risk to health when properly used.
Provide clear information about the safe use of their products.
Make available information about research and testing.
People in control of workplace (that is building owners who are not the employer) must
ensure that the workplace including entrances and exits is safe and without risks to safety and
health.
Section 18(1) of the Act, require that an occupier of a non-domestic premises which has been
made available to persons, not being his employees, as a place of work, or as a place where
they may use plant or substance provided for their use there, shall take such measures as are
practicable to ensure that the premises, all means of access are available for use by persons
using the premises, and any plant or substance in the premises or provided for use there, is or
are safe and without risks to health.
2.2.9 Occupational Safety and Health Policy
The employer must prepare a written statement of his general policy with respect to the safety
and health at work of his employees and the arrangement for managing safety and health in
the workplace. It should begin with a policy statement on how the employer intends to
comply with the law. The statement should be based on an identification of the hazards and
an assessment of the risks in the office. Employees should be informed of the policy. The
risks assessment results should be incorporated into the safety and health policy where
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appropriate. In preparing the statement it is useful to review the most common causes of
office accidents and if these hazards exist in your office, deal with them in the statement. The
statement should name those person in the office who are responsible for ensuring that safety
controls are put and retained in place.
3.7 First Aid Box
A first-aid box should be available in the factory and kept fully stocked. Someone should be
appointed to look after it, take charge in an emergency and call an ambulance. The factory
should have an appropriate number of trained first-aiders, depending on the risk involved, the
accidents likely to arise, the size and location of the office, the distribution of employees and
the distance from external medical services.
3.8 Accident Reporting
The Occupational Safety and Health Act 1994 require an employer to notify the nearest
occupational safety and health office of any accident, dangerous occurrence, occupational
poisoning or occupational disease which has occurred or is likely to occur at the place of
work. For further detail please refer to the Occupational Safety and Health (Reporting of
Accident, Dangerous Occurrences, Occupational Poisoning and Occupational Diseases)
Regulations.
3.9 Safety and Health Training
The types of training required for workers include:
Induction - so that new entrants get to know the basics such as fire evacuation, goodhousekeeping, electricity and VDU safety and the safety and health policy.
Skill - so that staff who have specific responsibilities under the safety and healthpolicy can undertake them in a competent manner e.g. manual handling training,
VDU assessment, office inspections and accident investigations.
Management training - which gives a good overview of the law including guidanceand need for risk assessment and preparing safety management programmes.
For a well organised office the safety and health policy should spell out the training
programme and commitment to provide resources to implement it. The key to induction and
skill training is that office workers require the knowledge to do what is expected of them.
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Management training involved in particular understanding the process of risk assessment and
their legal obligations. The training can be based on the accident trends for the office
environment such as slips, trips and fall, back injuries from manual handling, upper limb
disorders etc.
4.0 Conclusions
To sum up, it is crucial that all of the above issues and suggested solutions are addressed as
soon as possible and measures to be taken and implemented are evaluated and monitored.
This can be achieved through collating anecdotal evidence and through revision of incident /
hazard statistics for the area. Once the desired outcome has been achieved through
implementing the appropriate controls, the monitoring of the systems must be on-going to
ensure that control measures are maintained and do not become out-dated. The results will
provide our company with sufficient information to ascertain our effectiveness in controlling
hazards in the workplace and provide positive feedback for staff that shows that management
are committed to providing a safe working environment.
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REFERENCES
1. Health and Safety in the Office; The New South Wales Government;
Work Cover Authority;1993.
2. Guidelines on the Health and Safety of Office Workers; Health and Safety
Authority, Ireland.
3. Higher Productivity and A Better Place to Work, Practical Ideas for Owners and Managers
of Small and Medium-Sized Industrial Enterprises; J.E. Thurman, A.E. Louzine,
K.Kogi; International Labour Office, Geneva,1988.
4. Fitting the Task to the Man, A Text Book of Occupational Ergonomist; E. Grandjean;
Taylor & Francis; 4th. Edition, 1988.
5. Occupational Safety and Health Act 1994.
6. The Occupational Safety and Health (Safety Committee) Regulations.
7. Guidelines for the Interior Lighting and the Visual Environment;
Department of Occupational Safety and Health, Malaysia.
8. Sick Building Syndrome; Reality, Myth and Mystery; D. M. Rowe;
Department of Architectural and Design Science, University of Sydney.
9. Guidelines on First-Aid Facilities in the Workplace; Department of Occupational Safety
and Health, Malaysia.
10. The Occupational Safety and Health (Reporting of Accident, Dangerous Occurrence,
Occupational Poisoning and Occupational Diseases) Regulations.