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Job Safety Analysis and Risk Assessment A case study of Frontier Ceramics Ltd

Conference Paper · October 2018

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 Job Safety Analysis and Risk Assessment
A case study of Frontier Ceramics Ltd
Author1: Zahid Hussain
Department of Technology
Sarhad University of Science and Information Technology, Peshawar, Khyber Pakhtunkhwa, Pakistan
Email: zahid.btech@suit.edu.pk
Phone Office +92-91-5230931-3

Author2: Dr.Wasal Khan

Associate Professor, Department of Education
Sarhad University of Science and Information Technology, Peshawar, Khyber Pakhtunkhwa, Pakistan
Email:wasal.edu@suit.edu.pk
Phone Office +92-91-5230931-3

Author3Jehan Zeb Khan

(PhD Scholar at Department of Agricultural Engineering,
University of Engineering & Technology (UET) Peshawar)
Deputy Registrar
Pakistan Engineering Council (PEC) Regional Office
18/B-1 Phase-V Hayatabad Peshawar
Email: jehanzeb375@yahoo.com
Phone Office +92-91-5816537 – 9217880- 03018342084

Abstract.
The aim of this work is to identify those potential hazards that could be the risk of job place accidents and to take
preventive measures to reduce the intensity of accidents. Any ceramic industry dealing with the manufacturing of
wall tile, glazing is the most important operation for creating lustrous effect tile surface. Glazing line machines
composed of such mechanisms that need extremely care to deal with as it may easily cause personal injury to
concern operators. In order to minimize the rate of hazards pertaining to glazing line section, appropriate safety
arrangement is to be employed for the safe working environment of the workers. In this regard Job Safety Analysis
(JSA) technique is conducted to identify potential hazards on each job place. It also creates connection among
concerned operator, worker, job place, task, equipment and tools used and the working environment. The section
composed of Tile edge cleaner (grinder), double disc spray booth, glaze pump with agitating tank and vibrator,
water scraping machine, automatic glaze tiles printing machine, open chain drives and tiles table conveyor and
working with v-belts replacement. The required data for calculating quantitative risk has been collected by direct
observation of concerned supervisors recorded at various shifts. The study explored that 148 injuries of finger
amputations due to V blest replacement were recoded during year 2012. Similarly glaze pump agitating tank and
vibrator risk assessment score was recorded at highest level of 20. After conducting the analysis and assessment
procedure, a number of possible preventive measures are suggested and communicated to all the employees engaged
with glazing line operation. These techniques are designed to provide information for decision- making processes in
all similar industries dealing with manufacturing processes.

Key words: Accident frequency, Frontier Ceramics Ltd, Glazing line, Health hazards, Job safety analysis,
Occupational health, Risk Analysis, Risk Management.
 1. Introduction
M/s Frontier Ceramics (PVT) Ltd Peshawar incorporated in 1982 and playing a vital role in overall
growth of the national economy of Pakistan. The Company is engaged in the manufacturing of ceramics
tiles with brand name “FORTE” which has created strong loyalty in the market. Its wide range of
products includes:

• Domestic and commercial tableware and giftware;

• Floor and wall tiles;
• Industrial ceramics and refractory.

Pertaining to Job Safety Analysis and Risk Assessment, various techniques are introduced in order to
make a job place more secure in case a certain accident occurs. Obviously many of the industrial
accidents could have been prevented with proper safety precautions. Obviously there are numerous
industrial machines which are extremely dangerous to work with and hence thousands of workers become
injured through accidents. These injuries are caused either through negligence, accident or through
incompetence. Hence it is the responsibility of the employer to protect their employees against any
possible hazards in the work place and to provide trained staff and information to ensure they are aware
how to keep safety in the workplace [8]. The aim of risk identifications to detect those potential hazards
that could front a risk related to job place hazards and to take safety measures initiatives in order to
minimize the rate of accidents [7]. It is also noticeable that several accidents mostly occur in workplace
due to lack of inattentiveness of workers, necessary knowledge to perform certain task and especially
when working with new machines [2]. In order to control such incidents it becomes unavoidable to take
necessary steps to make job places safe by assessing the risks and suggest preventive measures. One way
to detect such accidents is to conducts job safety analysis which provide preventive measures for potential
hazards [3]. This technique is based on specific training and awareness with competent procedures for
works by responsible individuals. Implementing an effective job safety analysis management program, a
safe job place is guaranteed with improved level of awareness [4]. In order to produce a quality product
that will meet the requirements of consumers, a manufacturing unit should have an advanced technology
but certainly it will have a critical impact to concerned employees that will create a negative consequence
on the overall working atmosphere. As accidents are common in any workplace, the role of management
of occupational health and safety regarding job place is crucial to diminish the negative effect of a
production process [1].

Ceramic tile manufacturing process is based on a series of different process as shown in Figure 1 however
for analyzing JSA and Risk Assessment purpose, only glazing line as shown in Figure - 2 is selected due
to high frequency of injuries where 148 employees have suffered during the year 2012. Therefore the
corresponding author on the consent of higher management, conducted job safety analyses in order to take
necessary precautionary norms to reduce the rate of injuries in this particular section. Supporting
machines include high speed machines like Tile edge cleaner (grinder),double disc spray booth, glaze
pump with agitating tank and vibrator, water scraping machine, automatic glaze tiles printing machine,
open chain drives and tiles table conveyor and V-belts replacement during breakdown. Obviously the
concerned operators are exposed to high degree of injuries and by conducting risk analysis and
assessment, it will recognize possible damages that occur with their conceivable reasons followed by the
severity of the injuries.

Figure1. Ceramic tile manufacturing process

Figure 2. General view of glazing line

The aim of this study is to identify the potential hazards and assess the associated risk for a better and safe
approach through Job Safety Analysis (JSA) which will guide to find the precise explanations to diminish
job place accidents within the captioned plant.

2. Job Safety Analyses (JSA)

For identifying and ranking various hazards, it is necessary to establish and analyze necessary steps for
conducting job safety analyses. They are categorized as follows:
Step 1: selecting the job: The most critical job is the glazing line section where accidents occur
frequently that result in disabling injuries and most frequently among them is the finger amputation as
shown in Figure - 3. Hence glazing line section is designated to conduct job safety analysis while for
instance the accidental record for the year 2012 with total number of injuries is tabulated in Table-1 and
graphically shown the impact of each accidental event in Figure-4.

Figure 3. Finger amputation injuries

Table 1: Glazing injuries record for the year 2012

Month Tile edge Spray Glaze Water Automatic Chain V belts

cleaning booth pump & scraping printing drives drives
grinder agitator machine machine

Jan 13 5 8 1 3 5 10
Feb 17 6 9 0 5 4 16
Mar 13 7 4 0 2 4 10
Apr 11 9 7 1 0 0 9
May 11 11 6 5 3 3 15
Jun 10 6 10 2 0 5 20
July 9 1 8 4 0 1 13
Aug 8 4 8 6 5 5 4
Sep 7 3 3 2 3 3 18
Oct 6 1 6 0 0 0 10
Nov 5 7 4 1 0 3 11
Dec 3 8 3 0 2 0 12
Total 113 68 76 22 23 33 148
 Figure 4….: Graphical comparison of injuries for year 2012

Step 2: Breaking down the job into sequence of steps: This part of analysis is usually prepared by
knowing or watching a worker when doing his job. Here the job is splitting up in various operations and
the successful completion of that job in a appropriate sequence leads to the completion of overall job.
However if a certain job is ignored out it will definitely cause potential hazards. Glazing line section
contains such process operations that demand skillful capabilities. Hence the section is breaking down
into sequence of the following tasks:

Step 1: Experience, knowing, necessary skills required to operate glazing line machines.
Task 2: The knowledge required to connect each machine to its energy input components.
Task 3: The knowledge required to disconnect each machine to its energy input components
Task 4: Emergency stop procedure for entire section.

Step 3: Identification of potential hazards for every task: Based on observations of each specific
job, following are the steps that could go wrong at each step that basically help identify potential hazards
hence the use of following questions is very supportive:

 Can any body part get caught in or between objects?

 Do tools, machines, or equipment present any hazards?
 Can the worker make harmful contact with moving objects?
 Can the worker slip, trip, or fall?
 Can the worker suffer strain from lifting, pushing, or pulling?
 The worker exposed to extreme heat or cold?
 Is excessive noise or vibration a problem?
 Is there a danger from falling objects?
 Is lighting a problem?
 Can contact be made with hot, toxic, or caustic substances?
 Are there dusts, fumes, mists, or vapors in the air?
Step 4: Assessment of Identified hazards: The identified hazards are assessed using assessing the
risk quantitatively i.e taking in accounts the severity, probability and consequences of occurring an event
using the following criteria:
 Severity
With respect to probability or frequency, the following classification is used:
1 – negligible, will not cause injury or illness
2 – marginal, may cause minor injury or illness
3 – critical, may cause serious injury or illness
4 - catastrophic, may cause death

 Probability
With respect to probability or frequency, the following classification is used:
1. very unlikely: less than once per 1000 years i.e yearly probability 1:1000;
2. unlikely: once per 100 years i.e yearly probability 1:100;
3. quite likely: once per 10 years i.e yearly probability 1:10;
4. likely: once per year;
5. frequently: once per month or more frequently.

 Consequences
Also for the consequences five categories are used:
I - does not result in injuries
II - minor injuries
III - major injuries
IV - death or total disability
V - death or total disability for several persons.

Step 5: Determining Preventive Measures: Final step in conducting JSA is to determine possible
approaches to eliminate the hazards. In this regards the hazard control strategy is normally applied to
establish the preventive measures. They are:
1. Eradicate the potential hazard.
2. Replace the potential hazards with non-hazardous options.
3. Diminish the risk by implementing the use of personnel protective equipment and clothing.
4. Put into practice organizational control.
5. Ensuring to have an emergency system in concerned place.

3. Risk Assessment
According to classical explanation of risk, risk basically proportionates an extent for the
probability P of a certain event i.e the frequency, likelihood etc and the possible consequences C
of that particular event i.e impact or effect on aims:
𝑅 = 𝑃𝐶 (1)

Making assumptions on the basis of this particular definition and simplifications there of to
calculate the expected risks hence value of PC should be less or equal the critical value of that
risk i.e
 𝑃𝐶 ≤ 𝑅𝐶 (2)

If the classical annual de minimis fatalities risk is about 10-10 a-1then typically more inequalities
are need [6]. i.e

𝑃 ≤ 𝑓1 (𝑃, 𝐶) (3)

𝐶 ≤ 𝑓2 (𝑃, 𝐶) (4)

That typically necessitates that the given frequencies and consequences must conform those
inequalities which will be contingent on both the frequency and consequences correspondingly.
While oversimplification equation-2, it becomes probable to sure the risk by comparatively more
composite function than the constant critical value (Rc) is:

𝑃𝐶 ≤ 𝑓3 (𝑃, 𝐶). (5)

3.1 Risk Management Scheme (5 – Steps)

A 5 step risk management process should include the following as shown in Figure 5

 Establish context: illustration of concerned situation that explain issues regarding

personnel health and safety.
 Identification of Risk: The scheme of describing potential hazards sources and damage
scenarios that involve of individuals or entities.
 Analyzing Risk: Necessary analyses of risk evaluation based on probabilities and consequences

in case an event occur.

 Risk Evaluation: Justification of risk priorities on the bases of acceptance and rejection that
will judge the risk levels.
 Risk Treatment: It is better to adjust the preliminary condition for those risks which are not
acceptable.
Figure 5. 5 Steps Risk management process

4. Methodology:

4.1 Conducting Job Safety Analysis (JSA)

Necessary data for conducting for conducting the analysis has been collected by observations recorded in
three working shifts of the plant is shown in Table 2 for the following machines of glazing line:

 Tile edge cleaner (grinder)

 Double disc spray booth
 Glaze pump with agitating tank and vibrator
 Water scraping machine
 Automatic glaze tiles printing machine
 Open chain drives and tiles table conveyor
 Working with V-belts replacement
 Tables 2. Job Safety Analysis of glazing line.

No Machine Nature Type of Hazard Consequence P S CC Score

of Job
1 Tile edge Grinding of Direct contact of Finger’s 3 2 I 6
cleaner Tile edges operator’s fingers hand Injury
(grinder)

2 Double disc Water supply Direct contact of Lacerations on 4 2 II 8

spray booth for Tile operator’s fingers fingers, hands,
surface during spray fractures,
nozzles
regulation
3 Glaze Pump Continuous Direct contact of Finger’s or 4 5 IV 20
agitating agitating, fingers/body with hand and head
tank and vibrating of rotating lobes of Injury, possible
vibrator glaze agitator; broke; electric
vibrator machine shock
falling
4 Water Making Damages of body Fingers, hand 2 3 II 6
scraping smooth tile parts due to direct broke; broken of
machine edges contact, loose bones, respiratory
clothing, Slip, issues.
trip, fall
5 Automatic Printing of screen cleaning, Scratches, 3 3 III 9
glaze tiles glaze. Sliding parts of injuries, wounds,
printing machine Fingers cutting,
machine hand broke;
broken of bones.
6 Open chain Conveying of Damages of body Fingers cutting, 4 3 III 12
drives and tiles through parts due to table hand broke;
tiles table mechanized moving parts, broken of bones.
conveyor conveyor replacement
table
7 Working Replacement Avulsion of Finger 5 3 III 15
with V-belts supporting v fingertips, amputation
replacement belting in Fingers direct
running contact with
conditions mechanical parts
of v belt drive

Figure 6 shows the potential hazards which are categorized in a consequence probability diagram. For
convenience the consequences categories are presented at horizontal axis while the consequences growing
rightward. Correspondingly, probability categories are marked at the vertical axis, while the frequency
growing downwards.
So the following conclusions are made:
Machines with high level of risk: Glaze pump with agitating tank and vibrator (GP)
Machine expose to moderate risk : Open chain drives and tiles table conveyor (TC), Working with V-
belts replacement (VR) & Automatic glaze tiles printing machine (PM)

Machines with the lowest risk : Tile edge cleaner (grinder TEC), Water scraping machine (WSM) and
Double disc spray booth (DDSB) .

Accordingly to the demonstration of such type of probability consequence diagram, those events
(machines) with high level of potential hazards are located in the right side while those with low level of
risk in the left side of the diagram.

Figure 6. Probability-Consequences diagram (Risk Matrix)

4.1 Risk Control and Management

Based on Job safety and risk assessment values with accordance to the relevant probability, severity
and consequence categorical number identified, now it is intended to ascertain and rank controlling
measures to prevent future accidents. As a center for the process of decision making on which these
measures are to be implemented, tables 1 to 7 present the detail of controlling measure against each
machine as shown in Table 3 respectively.

Tables 3 Controlling measure of glazing line machines.

No Machine Consequence P S CC Score Controlling Measures

1 Tile edge Finger’s 3 2 I 6 Procedure follow up;
cleaner hand Injury Grinding disc material quality;
(grinder)

2 Double disc Lacerations on 4 2 II 8 Maintenance information

spray booth fingers, hands, display;
fractures, Ensuring earth system;
Water drain pipe permanent
fixing
3 Glaze Pump Finger’s or 4 5 IV 20 Operators’ training;
 agitating hand and head Vibrator fixing alternative
tank and Injury, possible system;
vibrator broke; electric Safety precautions
shock
4 Water Fingers, hand 2 3 II 6 Making sure to use working
scraping broke; broken of dress;
machine bones, respiratory Drain pipe permanent fixing
issues. solutions
5 Automatic Scratches, 3 3 III 9 Emergency stoppage
glaze tiles injuries, wounds, procedure follow up;
printing Fingers cutting, Operational procedure
machine hand broke; implementation follow up;
broken of bones. Safety precautions

6 Open chain Fingers cutting, 4 3 III 12 Provision of covers and

drives and hand broke; protective shields;
tiles table broken of bones. Worker concentration level;
conveyor Proper training

7 Working Finger 5 3 III 15 Use of an accident prevention

with V-belts amputation tag or sign on the power
replacement control allowed for permanent
stop of the pulleys system

5. Management review and decision

Based on the comprehensive results from both Risk analysis techniques and conducting Job safety
analysis along with probable consequences and controlling measures regarding glazing line safety, the
project owners hereby agreed to technically upgrade the glazing line processing system with
implementation of new safety system design as an alternative. The analysis methods are formal
documentation to demonstrate that this measure will provide considerably greater risk reduction than the
regular imposed measure. The process end with the authorities conclusion that the judgment of the risk
analysis conducted being reasonable and accepting.

6. Discussion and Conclusion

The objectives of this research work was to recognize the good and bad expectancy of work performing
by the workers working in glazing line section of Frontier Ceramics Ltd Peshawar. In order to expand the
research work, 10 supervisors from glazing line sections while 9 from maintenance department had been
selected for selection data at various working shifts. Accordingly a score based on risk analysis
techniques is calculated for various job places and machines/equipments of the captained section. Job
Safety Analysis and Risk Assessment techniques were conducted that showed highest level of risk with
probability, consequence and severity background approach for glaze pump agitating machines. The same
techniques were applied on whole glazing line machines that discovered various levels of scores along
with potential hazards. However it is necessary that preventive measures selected must be communicated
to all the employees engaged with glazing line operation. Similarly possible suggested controlling
 measures were also presented though this work. These techniques are designed to provide information for
decision- making in all similar industries dealing with manufacturing processes.

7. References

[1] Tsarouhas. Classification and Calculation of Primary Failure Modes in Production system,
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[2] Sankar, N.R, Prabhu B.S. Modified approach for prioritization of failures in a system failure
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[3] Jones, J. T., Berard, M. F. Industrial Processing and Testing. Iowa State University
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[4] Laflamme L, Cloutier E. Mechanization and risk of occupational accidents in the logging
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[5] Oggero A, Darbra R.M, Munoz M, Planas E. J. A survey of accidents during the transport of
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[6] Pasman, H.J, Jung S, Prem K, Rogers W.J, Yang X. Is risk analysis a useful tool for
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[7] Duijm N.J, Goossens L. Quantifying the influence of safety management on the reliability of
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[8] Hurst N.W, Young S, Donald I, Gibson H, Muyselaar A. Measures of safety management
performance and attitudes to safety at major hazard sites, Journal of Loss Prevention in the
Process Industries 9 (2) 1996.

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