MEM 603 CASE STUDY

MFORCE BIKE HOLDINGS SDN.
BHD.

Introduction
• A group of 5 students in semester 7 of the
Bachelor of Mechanical Engineering
(Manufacturing) from the Occupational Safety
and Health (MEM603) class group A
participated in an industrial visit to MFORCE
BIKE HOLDINGS SDN BHD, which is located at
Bukit Mertajam, Pulau Pinang. The company
specialized in the assembly of SYM motorcycles
and scooters in Malaysia. SYM is a motorcycle
brand from the Sanyang Motor Co. Ltd, a
company based in Taiwan.

OBJECTIVE
• To design and develop the complete
Occupational safety and health program for
an industrial organization.
• To apply the theories and knowledge
gained from lecture in an industrial
environment.

Part A- Identify the facility for
occupational safety and health that
should exist on the site
PESENTER KHAIRUL NIZAR

During our visit at the SYM Factory, we had observed some safety facilities
that are provided by the company. For example:

Fire Sprinkler
•Discharges water when the effects of a fire
have been detected

Smoke Detector
•Smoke detector is a device that senses
smoke, typically as an indicator of fire

Fire extinguisher and Fire hose •Fire and safety equipment Smoke ventilation system •Remove smoke from a building •Welding smoke and exhaust smoke .

This can increase muscle strain and also risk of falling due to improper handling.In order to improve the quality of safety at the factory. LIFTING EQUIPMENT . particularly in the use of sling where necessary  Always ensure that the weight and distribution of load is not beyond the capacity of equipment being used. there are some facilities that could be provided or improved by the SYM Factory. 1.The frames were lifted by had from the trolley to the assembly line.  A hoist is a device used for lifting or lowering a load  Train all the users. Recommendation  The use of hoist can reduce the risk of frames falling to the floor or worker. .

• Lifting operation are planned. .The law and regulation on lifting equipment • Lifting equipment is sufficiently strong and suitable for the proposed used and marked indicates its safe working load. • Lifting equipment is positioned or installed to minimize the injury risk. supervised and carried out in a safe manner by people who are competent • Lifting equipment is thoroughly examined for any defect before it is put into service for the first time.

.The tools that the workers use such as the air gun produces a loud noise.Exposure to high levels of noise can cause permanent hearing loss Recommendation  SYM Factory could provide personal protective equipment (PPE) headset as methods to overcome noise control . NOISE CONTROL .2.

Changing or modifying walking surfaces is the next level of preventing slip and trips. .Preventing falls due to slip & trips • Both slips and trips result from some a kind of unintended or unexpected change in the contact between the feet and the ground or walking surface • Some parts of the floor are oily due to engine oil spill. Recommendation • Housekeeping . It includes: ▫ cleaning all spills immediately ▫ mopping or sweeping debris from floors ▫ removing obstacles from walkways and always keeping them free of clutter ▫ keeping working areas and walkways well lit • .Good housekeeping is the first and the most important level of preventing falls due to slips and trips. Recoating or replacing floors and installing mats can further improve safety and reduce risk of falling.Flooring .

Regarding the maintenance program. SYM Factory had implemented the maintenance and testing of fire safety equipment. • All fire doors and escape routes should be regularly checked along with associated lighting and signs • Fire-fighting equipment should be regularly checked • Fire detection and alarm equipment should be regularly checked • All other equipment provided to help means of escape arrangements in the building should be regularly checked • Instructions for relevant employees about testing of equipment should be available to make sure those who test and maintain the equipment are properly trained to do so . The maintenance and safety are as follows.

we had observed some communication ways that SYM had implemented. Walkie talkie • A walkie talkie is a hand held. portable. . two way or multi-way radio transceiver.For the communication tool. • It was used by the supervisors and manager at the company to distribute information change and monitor the operation of the factory. For information distribution: 1.

ideal and actual production that should be done.To indicate the workers on the target.Visual communication .2. Production status display board . .

For safety purpose: 1. and that they know how to operate and respond to it  Ensure there are instructions/notices for employees on how to operate the fire warning system. Fire alarms and detectors  Ensure existing means of detection discover a fire quickly enough to raise an alarm in time for all the occupants to escape to a safe place  The means for giving warning should be clearly heard and understood throughout the whole premises when initiated from any single point  If the fire detection and warning system is electrically powered. . ensure it has a back-up power supply  Ensure employees know about the fire warning system.

OSH MANAGEMENT SYSTEM AT PRESENTER MUHAMMAD FAEEZ .PART B.

Daily Routine •Procedure check at the assembly line. •Morning talk about safety. . •Workers do self-check.

checklists Level 4 Records .OSH Documentation Level 1 Policy and Scope Level 2 Procedures Level 3 and forms Work instructions.

Flowchart of OSH Management System Policy Organisi ng Audit Planning & Implement ation Measuri ng Perform ance Reviewin g Perform ance .

Safety Procedure • Wear appropriate clothes given by the company. • Supervisors monitoring workers’ health and workplace conditions. . • Focus when working at the assembly line.

.Safety Committee Committee Members: • Management Representatives • Employee Representatives • Co-opted workers & others Frequency of Meetings • Every Monday. every week.

• Health and safety training. management or employee health and safety representatives. • Inspections of the workplace by enforcing authorities. and • Changes in the workplace affecting the health. . ill health. • Emergency procedures. sickness absence • Accident investigations and subsequent action. • Risk assessments.Safety Committee Responsibilities: • Statistics on accident records. safety and welfare of employees.

How-to assemble motorcycle parts accordingly. First Aid . Observing the workplace. Emergency training. Operating Machines and Tools. Possible harm.Awareness/Training • • • • • Fire Drill Training. .

Inspection Procedure .

Application of PPE • Gloves • Safety Boot Protections Safety Helmets Safety Apron Safety Goggles Ear .

Notification Warning .

Fire Alarm Fire Alarm Switch Fire Alarm Bell Fire Strobe Light .

Part C-Procedures & activities need to be carried out in the event of an Emergency/injury/accident/ incident PRESENTER MUHAMAD RAZWAN .

BHD • Escape Routes Employer do fire drill at least once per year to ensures employees know fire escape plan All escape routes are clearly marked and approve by fire brigade .FIRE Figure 1 : Escape Plan of MFORCE SDN.

Small fire .Fire extinguisher at workplace -Inspect regularly to keep in good working condition .Figure 2 : Fire extinguisher Fire Fighting .

Figure 3 : Evacuation plan of MFORCE SDN BHD Fire evacuations Assemble at evacuation assembly point Check employees have escaped safely .

FIRE PROCEDURE Sound fire alarm and alert all workers to evacuate Alert fire brigade Leave buiding immediately( escape route) Assemble with other staff at evacuation assembly point Inform firefighters of the situation .

When an injury or accident is known to have occurred: • First person nears victim must confirm exact location of the affected and the nature of the incident. organisation of person(s). • Confirm details of incident (name. • Send the victim to the designated Assembly Area. nature of injury/illness). • Report the details to the Supervisor. • Reporting and notification – refer to the Reporting injuries and fatalities procedure . • Notify relevant section manager as soon as possible. a person from the same organisation and known to the patient should proceed to the hospital. • When a patient is transported to hospital.

• First –aid Minor injuries Preventing further complications from injury .

PART D .What type of hazards that may occur and how are they avoided? PRESENTER AMIRUN NISYAM .

Fabric gloves are slippery which may lead to loss of grip while lifting the frames. b) Workers use fabric gloves while working. Risk of motorcycle frame to fall down a) The frames were lifted by had from the trolley to the assembly line. This can increase muscle strain and also risk of falling due to improper handling.1. .

. What type of hazards that may occur and how are they avoided? ▫ Suggestion 1 : The use of hoist can reduce the risk of frames falling to the floor or worker.D.

D. . What type of hazards that may occur and how are they avoided? ▫ Suggestion 2: The use of rubber/synthetic surfaced gloves reduces the risk of loss of grip.

What type of hazards that may occur and how are they avoided? 2. Noise a) The tools that the workers use such as the air gun produces a loud noise. . b) Constant exposure of this noise might contribute to hearing damage.D.

What type of hazards that may occur and how are they avoided? • Suggestion: The use of PPE headsets can reduce the stress on the hearing of the workers. .D.

D. Too much workforce on a single line ▫ The line is really packed with workers ▫ Collision might occur between the workers ▫ Workers might lose the grip of tools/components they are handling ▫ This can be hazardous and also costly ▫ Suggestion: Increase workspace area by preassembling certain parts outside the main assembly line . What type of hazards that may occur and how are they avoided? 3.

. Too much workforce on a single line ▫ The line is really packed with workers ▫ Collision might occur between the workers ▫ Workers might lose the grip of tools/components they are handling ▫ This can be hazardous and also costly ▫ Suggestion: Increase workspace area by preassembling certain parts outside the main assembly line. What type of hazards that may occur and how are they avoided? 3.D.

What type of hazards that may occur and how are they avoided? 4. Improper handling of assembled bikes ▫ ▫ ▫ ▫ ▫ The worker did not ride the bike properly Improper seat position Accidents can occur Slippery floor Suggestion: ride properly.D. .

E: COST OF PRACTICING OSH IN FACILITIES AND COMPARE WITH DOWNTIME COST PRESENTER MUHAMAD HAZIQ .

Facilities Costs Accidential Prevention Cost and Description Air compressor Motor: 7. 16 Bar) Compressor Speed 850 rpm Tank Capacity: 237 Liter Compressor Block Physical Dimension (L x W x H): 700mm x 460mm x 560mm Weight: 262 kg Dimension: 1470mm x 650mm x 1150mm Price: RM 10.5kw / 10hp Working Pressure (kg/cm²): 12 Bar (Max.600/unit .

Accidential Prevention Cost and Description Metal table Price: RM200/unit .

325/set .Accidential Prevention Cost and Description Gas welding (Oxy-Acetylene) Cutting torch dimension: 18” Price: RM 1.

Accidential Prevention Cost and Description Forklift Truck (Toyota) Load capacity: 2000 – 2500 kg Power: Diesel powered Price: RM28.000/unit .

000.00 per person Developing effective SHC RM 2.00 per person PPE training RM 80.Planning costs Accident Prevention Hired OSH officer Planning cost RM 42.00 .000.000.00per year Safety audit Safe handling of forklift truck RM 500.00 per person HIRARC training RM 4.00 per person Welder RM 1.000.

RM 10.000.Incident costs Incident Consequence Estimated cost Using hand tools Eye damages.000.00 Frequent lifting Sore muscle. strain RM 500.00 .00 serious long term illness Blocked fire exits Difficulties when incident occur RM 100.000.000.000.00 Wet and greasy floors Slip.00 Uncovered machine Hand get caught into rotating part RM 10. hearing loss RM 50. cuts and gashes. trips and falls RM 30.00 Constant loud noise Damage hearing. fatigue.

00 Stairs-Frayed Carpet Slips and trips RM 2000.00 RM 8000.00 Frequent lifting Using hand tools RM 20 000.00 RM 500.Comparison between preventive and Incident identification Preventive cost incident costsIncident cost Uncovered machine RM 10 000.00 RM 500.00 RM 200.00 RM 15 000.00 RM 400.00 RM 1000.00 Wet and greasy floors RM 30 000.00 RM 10 000.00 RM 9000.00 Constant loud noise RM 50 000.00 .00 Sharp chip formation RM 5000.00 RM 8000.00 Blocked fire exits RM 100 000.00 At doorways (rain).00 RM 10 800. spillages Improperly cleaning chip RM 500.00 RM 8000.

this visit provided us a better understanding on the use of Occupational Safety and Health in the workplace. the company practices safe working environment. we were able to understand how Occupational Safety and Health is applied in the company. although there are room for improvements. Overall. Other than that.Conclusion • From the industrial visit. In conclusion. . we were also able to identify the hazards that are involved in the manufacturing site and also how the company is able to prevent the hazards from happening.