BACHELOR OF MANUFACTURING MANAGEMENT WITH HONOURS

SEMESTER SEPTEMBER 2022

XBOH2103

OCCUPATIONAL SAFETY AND HEALTH MANAGEMENT

NO. MATRIKULASI : 000330070889001

NO. KAD PENGENALAN : 000330070889
NO. TELEFON : 013-7335106
E-MEL : kubendhran@oum.edu.my
PUSAT PEMBELAJARAN : SEBERANG JAYA LEARNING CENTRE
 INTRODUCTION

The use of paper in this era is very diverse because it is not only a mediating medium
of writing but it has also been diversified in several industrial sectors. The paper production
process has several process stages.

The paper production process will go through procedures such as the preparation and
handling of raw materials, pulp production, pulp washing and filtering, chemical recovery,
bleaching, stock preparation and finally paper making. Each of these processes requires very
careful and careful work steps and preparations. This is because hazards can be triggered
from various ways such as equipment, heavy machinery, work environment and equipment
machines. Every process has a very high risk and can result in physical, mental and
equipment damage.

As a safety and health officer appointed by Tony Production Company in their paper
factory, I have been asked to examine and analyze several things such as identifying hazards
in each process , made control measures for the hazards found and suggested some training
and provided standard operating procedures (SOP) for each process.

After analyzing these things, I was able to list some safety and health needs in the
paper manufacturing industry. Here too, I include some steps that we should take to improve
and prevent.
QUESTION 1:

a) Raw material preparation and handling

The most common point is slipping and falling from the tree. Because when cutting tall
trees has a very dangerous risk if there is negligence during the cutting process or not using
the appropriate equipment can cause slipping or falling. This can cause serious injury and
death.

In order that second point is wood ash when cutting the tree. During the process, there
will be dust released when the tree is cut down. If employees don't have complete PPE
clothing on, sharp wood dust can hurt their eyes and nose.

Next, the noise coming from the saw during this process can also cause ear injuries. It
also goes through a long phase.
 b) Pulp Manufacturing

Equipment. Poor maintenance of equipment and incorrect use of equipment can result in
damage to equipment and accidents during use resulting in injury to workers.

Electric and magnetic fields. The usage of devices with high magnetic fields and electric
currents can pose serious risks and result in long-term harm.

Signboard. Incorrect storage of the stock mixture and damage to the stock can come from
errors or carelessness in labelling.

c) Pulp washing and Screening

Chemical substance. Uncontrolled chemicals can create uneven pulp and pulp damage.

Fire or explosion. If high-powered devices are near chemicals, they can quickly catch fire.

The residue is filtered. Workers may be injured if the filtered residue is splashed.
 d) Chemical Recovery

Oxygen Tank. Workers may be burned if a fire breaks out.

Place Temperature. Inappropriate temperatures can cause environmentally sensitive

compounds to respond.

Chemical substance. Workers are exposed to potentially harmful chemicals.

e) Bleaching

Fire and Exploration. If sensitive chemicals are not properly managed, they can catch fire.

Skin erosion. Many chemicals are employed in this process. If exposed to chemical risks,
negligent and unsuitable use might result in skin erosion.

Pulp Brightness. Chemical measurement errors

f) Stock Preparation

Head box. Damage and harm to workers can result from improper handling and upkeep.

Pulp Cutter. Employee negligence can cause injury.

Debris from waste. Workers can sustain serious injuries if waste debris strikes them.

g) Papermaking

Fire: There is a lot of fuel in this process

Cylinder reservoir : There is still excess water on the paper

QUESTION 2

a) Raw Material Preparation and Handling

Slipping and falling Supervisors should ensure that workers use suitable and neat safety
from the tree ropes and safety equipment. This is due to the fact that the workers'
casual attitude and negligence are the primary causes of accidents.
Wood ash when When cutting wood, wearing a facemask and goggles can limit the
cutting the tree chance of powder or wood dust entering the cavities.

The noise The use of 'Safety Ear Muffs' can lower the intensity of the sound
produced by wood cutting instruments.

b) Pulp Manufacturing

Equipment Before using the equipment, staff receive proper equipment

maintenance and training on how to use it. This not only reduces
the danger of an accident, but it also increases the life of the
equipment.
Electric and magnetic Machines should be maintained according to the schedule so that
fields there is no risk of worker accidents such as short circuits and so on.
Signboard Storage area signs and labelling should be carefully located to avoid
chemical mixing and worker confusion.

c) Pulp washing and Screening

Chemical substance Workers must carefully control and monitor the chemicals that have
been mixed in order to avoid damage or confusion.
Fire or explosion Because sensitive compounds can be classified as fuel, diffuser
machines and chemicals should be located far apart to avoid a
reaction that produces a fire.
The residue is filtered The pulp screening procedure should include warning signs to
ensure that the filtered residues do not come into touch with the
workers.
 d) Chemical Recovery

Oxygen Tank Workers must wear protective attire when handling the oxygen tank
so that they do not burn or die if there is an accident while using it.
Place Temperature Chemicals must be stored at the appropriate temperature, the
location of chemical recovery should be separated by a suitable
distance so that chemical reactions do not occur.
Chemical substance Workers should be warned about the dangers of chemicals by
posting warning signs.

e) Bleaching

Fire and Exploration To avoid a fire caused by a sensitive chemical reaction, it is

prohibited to smoke or transport fuel.
Skin erosion To prevent skin erosion, workers must wash their faces and hands
with anti-chemical soap.
Pulp Brightness Chemicals must be accurately calibrated in order to avoid problems
in paper manufacture.

f) Stock Preparation

Carton box To avoid damage and accidents, the carton box should be kept in
good condition at all times.
Pulp Cutter Pulp cutters must be handled with care and instruction.

Debris from waste Workers will be warned by signs placed near the carton box to
avoid being hit by debris.

g) Papermaking

Fire Since the location contains combustible materials, a fire

extinguisher is required.
Cylinder machine Cylinder machine can only be maintained by professional workers.
QUESTION 3

1. The factory should provide specific training on how to use risky machinery that
provide a high risk of accident in order to increase worker efficiency and expertise
when utilising them.

2. Practical instruction on how to chop trees and climb high areas for assigned staff can
also assist decrease the likelihood of accidents.

3. The plant should also require every employee in the chemical department to take a
training in order to properly handle chemicals and deal with chemical mishaps.

4. The factory can arrange an identity programme for each year to encourage employees
to be more responsible, professional, successful, and advanced in their job. This not
only reduces the chance of accidents, but it also produces high-quality job outcomes.

5. Finally, I believe that strong staff monitoring and supervision will make the
workplace more careful and safe.
QUESTION 4

RAW MATERIAL PREPARATION AND HANDLING

a) Choosing suitable and high-quality trees to be felled while wearing PPE safety
equipment.
b) Trees must be felled in accordance with the requirements.
c) The chopped timber will be hoisted onto the truck using heavy gear.
d) Arrange the wood in the truck with a crane in an organised manner, and bind it neatly
and securely with the required iron chain to guarantee safety during delivery.
e) Distribute the logs to the factory for processing.
f) The newly delivered logs will be transported to the storage facility using heavy gear
and organised according to the label.

PULP MANUFACTURING

a) The chips will be taken to the screening procedure, which will screen the chips that
have been cut to the required size standards. Conveyors will transport perfect-sized
chips to a storage area before they are employed in the Pulp Manufacturing Unit.

b) Chips for cooking A high-pressure tank may separate lignin and wood fibres using a
Digester machine. When pushing the pulp, a quality chip made to the exact
specifications will produce good results. The Kraft method, an alkaline procedure,
will be employed.

c) The Kraft method employs two chemicals: sodium sulphide (Na2f) and sodium
hydroxide (NaOH). In the digester, the chips will be cooked and converted into cotton
known as pulp.

PULP WASHING AND SCREENING

a) Using White Chemistry, dissolve Lignin till the required fibre is obtained. White
Chemistry is the outcome of two sodium sulphide and sodium hydroxide mixes.
Because the resultant water is black, fibre dissolved in White Chemistry is referred to
as Black Chemistry.
 b) The Black Chemistry process then proceeds to the Recovery stage in order to return to
White Chemistry.
c) Cleaning the pulp using a Diffuser machine until the lignin dissolved in it is fully
removed.
d) Filtration Process or Filtration Process to filter and clean the cooked pulp.
e) Particles- Dissolved particles in the pulp can be separated using a selective filtering
process. Fiber weights, dirt, wooden points, and plastic are among the items
separated. These materials will be sent to the given stream before being disposed of
appropriately.

CHEMICAL RECOVERY

a) Execute the Oxygen Delignification Phase to better clean the leftover lignin residues
in the pulp and reduce lignin residues for the following process.
b) Place the pulp in the oxygen tank with low pressure and high temperature. This
procedure can lower the amount of chemicals used in the bleaching process as well as
the environmental distance created by the environmental process.

BLEACHING

a) Carry out the Lightening Process to lighten the colour of the pulp and remove
contaminants from the pulp. This can clear the lignin contained in the pulp and
improve its brightness.
b) Depending on the required brightness, the bleaching procedure might be divided into
various steps. Each procedure also employs a unique set of chemicals. The following
chemicals are utilised in this process:
I) chlorine gas (C)
II) chlorine dioxide
III) Oxygen
IV) Sodium Hydroxidae
V) Sodium Chloridaf
VI) Enzymg
VII) Ozone
VIII) Hydrogen Peroxide
STOCK PREPARATION

a) The goal of this procedure is to process the fibre material from the Bleaching Process
and create stock.
b) The paper is then formed in the Carton Box stage.
c) Paper production is divided into two stages:
1) wet process and dry process.
2) Wet and winding processes
d) The wet process is the preparation, mixing, and formation of paper sheets in which the
water content is still quite high.
e) The dry process is a continuation of the wet process in which the residual water
content in the pulp is removed.
f) Fiber refiners, also known as Refiners, will cut and crush the pulp into little pieces to
strengthen the strength of the fibres between one other. When the pulp gets dry, it is
placed in the crushing tank and mixed with water to wet it before being fed into the
Refiners.
g) It is a paper sheet creation process, similar to the Formation Process, in which the
stock from the headbox spreads the pulp over a moving sieve called as a wire. During
the sifting process, the pulp is pressed against the wire, and 98% of the water is
pushed out. The wet procedure will come to a conclusion here.

PAPERMAKING

a) During the sieving process, practically all of the leftover water from the dry paper is
removed, leaving only a few water molecules in the pulp.
b) The created paper will be placed in a heated from the inside cylinder reservoir, and
this cylinder reservoir will eliminate water from the paper. It is during the drying
process.
c) This cellulose fibre will form a braid that is attached to one another and will form a
giant coil known as a winder that will aggregate into a large group.
d) This group will then be divided into smaller groups or sheets of paper before being
delivered to the consumer.
 CONCLUSION

After conducting multiple investigations into the procedures at this factory, I came to
the conclusion that there are still certain things that need to be addressed and fixed right away
in order to ensure the safety and health of the workers as well as the manufacturing of high-
quality paper goods.

If no preventative measures or upgrades are implemented, it can not only impact the
factory's production quality, but it can also raise the percentage of accidents that occur in the
factory as long as it is operational. If the specified training program's activities can be carried
out successfully with the collaboration of management and workers, it can not only lower the
danger of accidents, but it can also increase the quality of paper manufacturing.

I am also certain that the organization's safety and health regulations, as well as the
requirements of this law, may foster a culture of prevention in the paper production
operations. This may also make the workplace a more secure and healthier atmosphere.
TUGASAN 2