Curtin University Of Technology

Engineering First Year

Engineering Foundations: Principles and Communications 100

M-45 Final Site Visit Report:
Nam Cheong Dockyard (NCD)

Title

: Safety Culture of Nam Cheong

Dockyard

Name of site

: Nam Cheong Dockyard

Audience

: Company Managing Director

Name

: Wong Yee Jing

Miri Student ID

: 7E1B9107

Perth Student ID

: 15880909

Group

: 3A

Tutors name

: Billy Lau Pik Lik

Date of submission

: 12nd October 2012

Word count

: 1504 words (IntroductionRecommendations)

M-45 Final Site Visit Report

M-25

M-45
Name: Wong Yee Jing

Student Number: 7E1B9107/15880909

Tutor: Billy Lau Pik Lik

Seminar Group: 3

Engineering Report Structure

Tutor Feedback
Achieved

Failed to Achieve

Executive Summary: (concise, coherent and includes

recommendations)
Contents page: Appropriate use of language for intended
audience / thorough contents page with appropriate use of
decimal notation , informative headings and sub-headings
List of Figures and Diagrams: Title to every graphic and
appropriately referenced with page numbers
Introduction: succinct and coherent, purpose is clear,
audience is identified and site is mentioned
Body: evidence of analysis and observations relevant to the
site and its topic - supported with in-text referencing
Conclusion: succinct with adequate information appropriate for the intended audience
Recommendations: appropriate recommendations, relevant
to the topic and the issues presented in the report
Referencing: appropriate in-text referencing and reference
list - Chicago style format with at least five references
Graphics: evidence of appropriate integration of relevant
graphics, clearly labelled with in-text referencing where
necessary
Appendix 1: Final Reflection Your learning experiences
over the past 12 weeks (project and EFPC Unit)
Appendix 2: A copy of your M-25 with tutor-feedback

Improved Report:
In-class reflection (from week 7):
Appendix 1- Final reflection:

/35
/5
/10

Total

/50

GENERAL COMMENTS:

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M-45 Final Site Visit Report

I. Executive Summary
This report is presented to Company Managing Director on safety culture topic. After
analysing, the site visit has a good standard in health and safety because every visitor is given
safety helmet to wear in order to protect against risk hazard at the construction site. Nam
Cheong Dockyard allocates sufficient signboards and fire extinguishers which can reduce
danger risk working at factory. Nam Cheong Sdn Bhd has a well waste management system
to reduce harm to environment. There are some environmental impacts on the safety
surrounding area by plant which are air, water and noise pollution. In addition, Nam Cheong
Dockyard, its location has impacts on its safety plant due to equatorial climate and location
free from natural disasters in Malaysia. Hazardous conditions at the construction site are trip
hazard and electricity hazard. These two hazard problems can be addressed with good
housekeeping or replacement with new one for old electricity appliance or maintenance given
from time to time. Research was limited because there is a disturbance of high frequency
noise produced from machines that will distract our attention making down notes and
occasionally make our hearing not in good condition listening to the speech given by the site
conductor, Mr Tiong. In the methods of research aspect, there are primary and secondary
research be applied. A site visit to Nam Cheong Dockyard (NCD) is held in order to get
useful information about shipbuilding process and know more about the construction site.
The site visit provides a chance to gain additional knowledge on the operation of a shipyard,
safety measurements, and some processes of shipbuilding. The information and data in this
report is obtained based on secondary research which is internet source. Official website of
Nam Cheong is accessed to give more relevant evidences in this report. Recommendations
which are more PPE equipment should be provided, good housekeeping to maintain safe
environment, using eco-friendly material with low pollutants composition and reduce noise
pollution are proposed to improve Nam Cheong Dockyard. In a nutshell, although NCD has
followed the safety regulations to maintain safe working environment for employees, but
there is further improvement is needed in order to create a better and safer working
environment.

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M-45 Final Site Visit Report

Table of Contents

Title
1.0

2.0

3.0

4.0

Introduction
1.1

Purpose

1.2

Scope

1.3
Background of Nam Cheong Dockyard (NCD)
Plants Impacts on The Safety of The Surrounding Area
2.1

Air Pollution

2.2

Water Pollution

2.3
Noise Pollution
Impacts on Plant Safety of The Location of Shipyard
3.1

Climate

3.2

Free from Natural Disasters

6.0
7.0
8.0
9.0

6-7
7
7-8
8
8-9

Hazardous Conditions In The Industry

4.1

5.0

Page

Old Appliance

4.2
Trip Hazard
Health And Safety
5.1

Personal Protective Equipment (PPE)

5.2

Fire Extinguisher

5.3
Safety Signboards
Conclusion
Recommendations
References
Appendix
9.1

Appendix 1: Reflection

9.2

Appendix 2: M-25 Site Visit Report

9-10
10-11
11-12
12-13
14-16
16
16-17
17-18
19-20
21

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M-45 Final Site Visit Report

II. List of Figures
Figure
Figure 2.21

Title

Page

River at Nam Cheong Dockyard(NCD)

(Photo Taken by Yee Jing, Wong 2012)

Figure 3.21

Position of NCD in Malaysia is located at

equator line

Figure 4.11

Old switches at the site

10

(Photo taken by Ruoh Chien, Goh 2012)

Figure 4.21

Fragmented pieces at BP (Bulwer Island)

11

Refinery Plant

Figure 5.11

Conductor of NCD who is equipped with

12

full PPE (Photo taken by Ruoh Chien, Goh

2012)

Figure 5.21

Fire extinguisher is hanged on side of ladder

13

(Photo taken by Ruoh Chien, Goh 2012)

Figure 5.22

Fire extinguisher is hanged near to the

13

assembly place of NCD (Photo taken by

Ruoh Chien, Goh 2012)

Figure 5.23

Fire extinguisher is put at the welding plate

13

area (Photo taken by Ruoh Chien, Goh

2012)

Figure 5.31

Safety signboards

before

entering

the

14

construction site (Photo taken by Ruoh

Chien, Goh 2012)

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M-45 Final Site Visit Report

Figure 5.32

Safety signboard near the tanks (Photo taken

15

by Ruoh Chien, Goh 2012)

Figure 5.33

Safety labels along the ship plate area

15

(Photo taken by Ruoh Chien, Goh 2012)

Figure 5.34

Safety signboard along the welding area

(Photo taken by Ruoh Chien, Goh 2012)

16

1.0 Introduction
1.1 Purpose
This report is written to Company Managing Director to analyze the safety culture of Nam
Cheong Dockyard. In this report, the people, equipment and environmental infrastructure of
the site visit will be looked through under the safety culture. Moreover, the importance of
safety assurances will be discussed. There are some recommendations are proposed in this
report for improvement based on the issues raised.
1.2 Scope
The scope of this report comprehends the environment impact of the plant, impact of the
location of the shipyard, hazardous condition impact by plant, and health and safety of the
site.
1.3 Background of Nam Cheong Dockyard (NCD)
Nam Cheong Dockyard Sdn Bhd was established in Sarawak in 1968. Nam Cheong Shipyard
stands out be the foremost Offshore Support Vessel (OSV) with a strong reputation in
Malaysia and the Southeast Asian Region as a builder of quality vessels. In 1987, the
company built the first high-tech Safety Standby Vessel for Sarawak Shell Berhad. Twenty
years later, Nam Cheong continues to break new ground by being the first shipbuilding
company to manufacture the first dynamic positioning 2 (DP2) vessel in Malaysia
(GlobMaritime 2012). The giant project that had completed by NCD is platform supply
vessel. NCD is currently focusing on extensive expansion and upgrading of current technical
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M-45 Final Site Visit Report

skills and technology to push to great heights in shipbuilding industry and be known for
major player in the world (Nam Cheong Dockyard Sdn Bhd 2012).
2.0 Plants Impacts On The Safety of The Surrounding Area
An environmental impact is defined as any change to the environment, whether adverse or
beneficial, resulting from a facilitys activities, products, or services. There are three main
impacts produced throughout the formalities and activities of the plant.
2.1 Air Pollution
Marine coating is one of the frequent processes of shipbuilding. The marine coating process
has caused harms to environment. Conventional primers and paints contain solvent and
pigments with heavy metals. Many solvents contain volatile organic compounds (VOC)
and/or Hazardous Air Pollutants (HAPs). Some VOC and HAPs will lead to the formation of
ground level ozone or smog (Environmental Impacts of Shipbuilding and Repair Operations
2008). Air pollutants change the composition of atmosphere and affect biotic environment
(S.P. Gautam 2009). Hence, chemicals used in coating process will lead to air pollution.

2.2 Water Pollution

Vessel maintenance is one of the unavoidable activities in shipbuilding. Ship maintenance

activities will produce liquid wastes such as oil, lubricants, hydraulic fluids and anti-freeze
(Environmental Impacts of Shipbuilding and Repair Operations 2008). Spills and leaks of
these liquids can harm marine life. Even very small quantities of oil will spread, floating on
the surface of the water covering vast areas of water . These thin sheets can kill marine larvae
which in turn decrease the number of marine life (Toxic Pollution 2012). Thus, liquid wastes
produced from the plants activities will lead to water pollution as shown in Figure 2.21.

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M-45 Final Site Visit Report

Figure 2.21 Polluted river at Nam Cheong Dockyard(NCD)

(Photo Taken by Yee Jing, Wong 2012)
2.3 Noise Pollution

Manufacturing process in shipbuilding and vessel noise generated by ships produce high
frequency noises to surrounding area. This form of pollution and its impacts towards marine
life and environment is hardly can be detected. According to OECD (2010), the movement of
the ships hull through the water and its machinery equipment have been being great
contribution towards noise pollution will cause high vibrations to surrounding area. Therefore,
noises generated from manufacturing process and ships vessel are the main sources of noise
pollution.

3.0 Impacts of the location of the shipyard

Climate change is inconsistent since NCD is located at Miri, Sarawak, a typical country with
equatorial climate. NCD has the high possibility to free from natural disasters.
3.1 Climate
Climate in Sarawak is inconsistent because it experiences monsoonal changes two times. The
average daily for minimum and maximum temperatures ranges between 23C during the
early hours of the morning and 32C at the peak of day. Miri is having comparatively longer

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M-45 Final Site Visit Report

bright sunshine generally in excess of 6 hours daily (Geography 2011). Workers have to
suffer since wearing protective clothing under hot temperature with long exposure duration.
3.2 Free from Natural disasters
Since Nam Cheong Dockyard is located in Malaysia, a country situated near the equator line
as shown in Figure 3.21, so it can be said that it is free from natural disasters. Due to small
possibility happening natural disasters like flood and earthquake, safety of plant can be
reassured. Explosion may occur due to explosive gas content inside gas cylinders and
hazardous chemicals used during process can threaten workers safety are the disasters for
NCD if careless and bad management from NCD. Therefore, NCD has high possibility to free
from natural disasters.

Figure 3.21 Position of NCD in Malaysia is located at equator line

4.0 Hazardous Conditions In The Industry

There is a high risk getting injured or hurt if there is no constant maintenance takes place to
resolve the poor conditions. Working condition is an important element that may influence
the employees health and safety. Risks occurring on the working stands may result from the
physical, chemical and biological agents.

4.1 Old appliance

Old appliances like old switches that function to connect the electricity to operate the electric
screw driver have been found out in a poor condition as shown in Figure 5.11. Contact with
live parts can cause burns and shocks (Electricity 2010). Shocks from faulty equipment can
cause severe and permanent injury. Electrical faults will lead to fires (Electricity 2010). Since

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M-45 Final Site Visit Report

electrical appliance in NCD is not well maintained, there is high possibility of fires happen in
NCD and employees safety is put at risk.

Figure 4.11: Old switches at the site (Photo taken by Ruoh Chien, Goh 2012)

4.2 Trip hazard

Trip hazard includes uneven floor surfaces, and obstructions on the floor. Uneven floor
surfaces scene is founded when there is fragmented pieces of metal and glass on the ground
as shown in Figure 4.21. If not, more serious slips or trips together with the resulting falls
will lead to damage of sprains or strains and broken bones when trying to break the fall.
Furthermore, a back injury due to the sudden and forceful impact during a fall also may
happen (Slips, trips and falls prevention 2007).

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M-45 Final Site Visit Report

Figure 4.21: Fragmented pieces from screenshot of

BP (Bulwer Island) Refinery Plant

5.0 Health and Safety

Nam Cheong Dockyard (NCD) precedencies health and safety policies to ensure that all
employees and visitors are committed to the health and safety measures in the factory.
Besides, maintaining safe working conditions and practices for all employees and providing
engineering controls also are carried out by Nam Cheong Dockyard Sdn Bhd. At the BP
(Bulwer Island) Refinery Plant, checking by engineers on the machines and compliance to the
health and safety regulations of site is important to make sure that working environment is
safe.
5.1 Personal Protective Equipment (PPE)

Where primary methods such as engineering and administrative controls are not appropriate
or sufficient to control the hazard, personal protective equipment (PPE) is required (Personal
Protection Equipment 2012). PPE program is implemented in NCD in order to minimize the
risk in working place. Different types of PPE can provide protection against risk at different
hazards. Safety helmets, gloves, eye protection, high visibility clothing, safety footwear and
safety harnesses are the examples of PPE. Figure 5.11 shows that some examples of PPE
need to be equipped with when entering factory.

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M-45 Final Site Visit Report

Safety helmet

High visibility clothing

Safety boots

Figure 5.11 Conductor of NCD who is equipped with full PPE

(Photo taken by Ruoh Chien, Goh 2012)

5.2 Fire Extinguisher

There is always a high potential of fire risks at anywhere in the construction site. Fire
extinguishers can be seen everywhere of the site just in case any fire or explosion hazard
occurs (Shown in Figures 5.21, 5.22 and 5.23). With this safety instrument during emergency,
small fire that caused by sparks or any other factor can be extinguished as fast as possible to
reduce the level of danger. Class A and B extinguisher are commonly selected to be used in
the site. Class A extinguishers are for ordinary combustible materials while class B
extinguishers are for combustible liquids (Fire Extinguisher Types 2012). NCD provides
sufficient quantities of fire extinguishers to reduce risk of fire hazards.

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M-45 Final Site Visit Report

Figure 5.21 Fire extinguisher is hanged on side of ladder

(Photo taken by Ruoh Chien, Goh 2012)

Figure 5.22 Fire extinguisher is hanged near to the assembly place of NCD
(Photo taken by Ruoh Chien, Goh 2012)

Fire
Extinguisher

Figure 5.23 Fire extinguisher is put at the welding plate area

(Photo taken by Ruoh Chien, Goh 2012)
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M-45 Final Site Visit Report

5.3 Safety Signboards

Each safety signboard can deliver warning or sign of danger to visitors and employees to stay
alert and keep away from dangerous. There are several types of signs can be seen around the
construction site. Regulatory signs or mandatory signs are signs signifying that an instruction
should be carried out and followed (Safety Concepts 2007). These regulatory signs are used
to show that specific requirements of PPE before entering the construction site or any areas as
shown in Figure 5.31. Prohibition signs indicate that an action of activity is prohibited such
as smoking as shown in Figure 5.32. Figure 5.33 shows that some safety labels with warning
purpose can be found along the ship plate area. Hazard signs carry warning of a hazardous
situation such as overhead crane hazard area as shown in Figure 5.34. There is sufficient
variety of safety signboards allocated in NCD to keep remind workers to stay alert to keep
away from danger.

Figure 5.31 Safety signboards before entering the construction site

(Photo taken by Ruoh Chien, Goh 2012)

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M-45 Final Site Visit Report

Figure 5.32 Safety signboard located near the oxygen tanks

(Photo taken by Ruoh Chien, Goh 2012)

Figure 5.33 Safety labels along the ship plate area

(Photo taken by Ruoh Chien, Goh 2012)

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M-45 Final Site Visit Report

Figure 5.34 Safety signboard along the welding area

(Photo taken by Ruoh Chien, Goh 2012)

6.0 Conclusion
In a nutshell, the safety culture of Nam Cheong Dockyard and BP (Bulwer Island) Refinery
Plant have been examined and analyzed in this report. The environmental impacts by plant
are air pollution, water pollution and noise pollution. Climate change and free from natural
disasters are impacts of location of shipyard. For hazardous conditions, electricity hazard and
trip hazard these two issues are highlighted. Overall, Nam Cheong Dockyard (NCD) has a
good standard in health and safety in this report. Even though NCD has achieved good
standard in healthy and safety, further improvements from NCD is still needed and highly
recommended to safeguard employees health and safety all the times at the workplace.
7.0 Recommendations

More personal protective equipment (PPE) such as ear protectors, safety boots, and
masks should be provided to visitors to give protection against noise pollution, risks or
hazards and prevent from inhaling dust and hazardous substances.

Good housekeeping and constant maintenance are needed in order to provide a better
quality working environment and to increase the health and safety standard as well.

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M-45 Final Site Visit Report

Likewise, constant maintenance by having regular check-ups and replacement for old
appliances can reduce the dangers at workplace.

Eco-friendly materials should come to first choice in each activity. Materials with low
composition of air pollutants is highly recommended be used to reduce the negative
impact towards environment.

Ensure that the fire extinguishers are recharged and replaced after seven years of service
as a preventive measure. If any fire hazard happens, it can be used to extinguish fire
without delay.

Reduce noise pollution through quiet power tools and equipment maintenance.
Replacement with new tools which are quieter can reduce the noise level to surrounding
area because old and second hand tools can generate noise sounds. Periodic
maintenance of equipment for generator units by replacing worn out parts and
lubricating rotating parts will less contribute to noise environment.

(1504 words)

8.0 Reference List

Chong Wing, Chia. 2012. Managing Flood Problems In Malaysia. Accessed October 6,
http://www.bem.org.my/publication/juneaug04/F%28Flood%29%2838-43%29.pdf.
Country Report of Malaysia. 2012. Accessed September 12,
http://www.adrc.asia/countryreport/MYS/2011/FY2011A_MYS_CR.pdf.

Electricity. 2010. http://www.healthyworkinglives.com/advice/workplacehazards/electricity.aspx.

Environmental Impacts of Shipbuilding and Repair Operations. 2008. Pacific Northwest

Pollution Prevention Resource Center (PPRC).
http://pprc.org/hubs/printfriendly.cfm?hub=32&subsec=3&nav=1.

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M-45 Final Site Visit Report

Fire Extinguisher Types (What Kind do I use?). 2012. Fire Extinguisher: 101. Accessed
September 5, http://www.fire-extinguisher101.com/.
Gautam, S.P. 2009. Hazardous Air Pollutants. Central Pollution Control Board Ministry of
Environment and Forests. Accessed October 6,
http://www.cpcb.nic.in/upload/Newsletters/Newsletters_64_COVER,%20SOFT,%20
BACK,%20EDITORIAL%20HAPs%20Newsletter.pdf.
Geography. 2011. State Planning Unit: Chief Ministers Department Sarawak. Accessed
September 11, http://www.spu.sarawak.gov.my/geography.html.
GlobMaritime. 2012. http://www.globmaritime.com/directory/70-Shipyards?site=91.
Nam Cheong Dockyard Sdn Bhd. 2012. Accessed August 28, http://sivamy.jobstreet.com/_profile/previewProfile.asp?advertiser_id=27720&dept_id=0.OEC
D Council Working Party on Shipbuilding. 2010.
Environmental And Climate Change Issues In The Shipbuilding Industry. Accessed
September2,http://www.oecd.org/sti/industryandglobalisation/46370308.pdf.
Personal Protection Equipment. 2012. NC STATE University: Environmental Health &
Safety. Accessed September 5,
http://www.ncsu.edu/ehs/www99/right/handsMan/worker/ppe/index.html.
Safety Concepts: Safety At Work. 2007. Accessed September 8,
http://www.safetyconcepts.com.au/safety-signs/.
Slips, trips and falls prevention. 2007. The State of Queensland ( Department of Employment
and Industrial Relations). Accessed September 2,
http://www.justice.qld.gov.au/__data/assets/pdf_file/0011/75962/slips_trips_falls_gu
ide2007.pdf.
Toxic Pollution. 2012. Accessed October 6, http://see-thesea.org/topics/pollution/toxic/ToxPol.htm.

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9.0 Appendix

9.1 Appendix 1: Reflection

Engineering Foundations Principles and Communications (EFPC) 100 is a challenging unit
that let me encounter the importance of communication is the most important element should
be sharpened and developed between designers and contractors. One of the challenging parts
is my company was assigned to design a bridge and build a mousetrap car. Throughout the
unit, I have learnt that good interaction between each other can make the progress to run
smoother and speed up the process since no arguments were raised. During the process, I
have expressed my opinions in open way and communicating in a more proper way and with
manners. I tend to communicate using simple words with my company members to avoid any
misunderstanding or conflict. If I am still confused with my tasks given, I would not
hesitatingly to reconfirm again with other members. For example in Stage 1, I am puzzled
about the tasks of the position of second secretary that I have been assigned to carry out my
responsibility. My thinking skill also has been improved because the ability to solve problems
that occurred throughout the process of this unit is more developed. For example, producing
tender submission to each different designing company in Stage 2 by fulfilling their
evaluation criteria is not an easy task as well. As contractor, my companion and I have faced
the shortage time problem since we need to produce three different tender submissions. First,
we have to analyze the TEC received from designing companies. After that, we would
provide solid evidences to support the tender submission. For budget criteria, we need to do
some surveys on the price of materials used to cut down budget as required by all designing
companies and need to care about the quality of materials in order to produce a good quality
product. After doing survey and analyzing, we have to adjust and make a quotation table for
total price of materials used by referring to quantities for each material used. Other than that,
teamwork spirit is also important to help our company to achieve all targets and goals. When
I face some difficulties in doing my task, I would hold a small discussion with my companion
who has same responsibility as me and seek suggestions or opinions from other team
members to help me settle those problems. For instance, when I have no idea what I am going
to do with the tender evaluation criteria and disposal plan, I would discuss and seek help from
another contractor in our company to resolve it by comparing each other task and finalize the
useful information can be used during the progress preparing Stage 1 report. I have learnt that
how to write minutes meeting report and weekly report throughout this unit and how to
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balance important and urgent stuffs. If there is urgent stuffs, I will quick my motion and use
time wisely on the right way. For important stuffs, I will prepare earlier and give the first
priority doing rather than other things. In Stage 3 which is called the construction process, the
preliminary vehicle product of us is found that not compliant to the client brief after checked
by designers. Besides, our mousetrap car has an alignment problem that makes it cannot
travel in a straight line. During modification process, we changed the compact disc material
into plywood as the front and rear wheel. We felt grateful under supervision from iTech
designers that had guided us clearly in constructing the mousetrap car project. Dimension of
the mousetrap vehicle also been changed in order to make sure that the product is compliant
to client brief. Constructing mousetrap car is not as easy as what I have thought before since
it has consumed more time that I have expected. During the handover process to designer and
client, both parties have made a dreadful mistake which is the handover form that needed to
hand in is incomplete without the signatures of designers to declare it. From this mistake, I
have learnt that we need be careful in doing everything and be self- independent because too
much reliance will lead to self-indulgent that can make people become careless. Moving
forward to Stage 4, our company members have put lots of efforts in preparing final
presentation. We discussed and allocated tasks properly besides had rehearsal practices
between each other. During testing day, our mousetrap car could travel at 14.15 maximum
distances and had 4 successful runs while our bridge could withstand 75 kilograms static load
after had pass through 5, 10 and 15 kilograms rolling load tests. After testing, we disposed
the components of vehicle according to disposal plan proposed by designers. At the end, our
company becomes the overall champion among opponents. In this unit, I also have
discovered that research skill is extremely important too. My research skill has been
developed to a better level since I had done so much research during Stage 1 and Stage 2
processes. I have used primary and secondary research in doing this report. During the site
visit, I had taken some photos to assist me doing this report. Moreover, the brief notes or talk
given by the conductor also had been marked down for further use purpose. I also had
accessed the internet to get more relevant information in doing the site visit report.
Furthermore, I used EFPC text book to guide me as well to produce a good quality of report.
In a conclusion, I am quite satisfied with myself performance with my team members and my
team members performance too as our company already achieved the mission and vision that
had been set earlier as we have strived excellence to get a fruitful result.

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9.2 Appendix 2:

M-25 Site Visit Report

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