INDUSTRIAL TRAINING

CYBERJAYA UNIVERSITY COLLEGE OF MEDICAL SCIENCES

Title:

WORKPLACE ACTION RESEARCH PROJECT 2

(OSH 3913)

Project:

HIRARC ON MAINTENANCE WORKSHOP

KONSORTIUM PD SDN BHD

Prepared By:

MUHAMMAD IQRAM BIN SULAIMAN

06 – DOSH 1605 – 7283

SUBMISSION DATE:

12 February 2019
Table of Contents

1.0 Abstract

i.1 Assignment background

i.2 Report objectives
i.3 Methods used
i.4 Result obtained
i.5 Suggestions and control measures recommended

2.0 Introduction
2.1 Company profile
2.2 Organizational chart
i. Pharmaniaga organizational chart
ii. Safety, Health, Environmental – Quality Committee organizational chart
2.3 Number of worker
2.4 Activities
2.5 Overall work processes
2.6 Specific work process

3.0 Objectives

4.0 Methodology
4.1 Three methods used in hazard identification process
4.2 Explain methods of risk assessment (risk estimation and risk evaluation)
4.3 Matrix used, explanation of likelihood and severity and decision for action

5.0 Result and Discussion

5.1 List and tabulate 6 hazards according to criticality of the risk
5.2 List hazard based on their rating
5.3 Rationalize your choice for the most critical hazard (1 physical and 1 health)
5.4 Explain impact of the most critical safety and health risks identified to the
organization
6.0 Recommendation
6.1 Explain detail of the proposed control measures (preventive and corrective) for the
most critical safety hazard
6.2 Explain detail of the proposed control measures (preventive and corrective) for the
most critical health hazard
6.3 Explain the proposed review program on the effectiveness on the proposed control
measures in subsection 6.1 and 6.2
6.4 Discuss the benefit of the recommendations in subsection 6.1 and 6.2

7.0 References / Sources

8.0 Attachment / Appendixes

1.0 Abstract

1.1 Assignment background

This report is about the assessment process of identifying hazardous act and condition
occurring or being practice in the identified and selected working area. Identifying the real
hazard occurs at the workplace will lead to the evaluating the risks this proper
implementation of the most effective risk control measures shall be taken to further improvise
the working environment / condition. The control measures are not limited to either
eliminating or risk reduction but beyond than that, it is about inculcating safety and health
culture in the organization.

The workplace assignment has been conducted at the Korsortium PD Sdn Bhd. The
main focus of hazards identification is at the maintenance section focusing on the mostly
carried out activity in this maintenance.

In order to achieve the main objectives in providing safer place of work, there are
several methods of hazards identification that has been applied such as workplace
observation, document review, conducting survey and interview. The result that has been
obtained will need corrective and preventive action as a continual improvement to this
working area so as to eliminate or reduce the hazard that is exposed to the persons at work.
The corrective and preventive action will be assessed using “hierarchy of control” in ensuring
the recommendations in eliminating or reducing the hazards exposed to the specific group of
persons at work is according to the most efficient control measures.

As for risk control principals, there are rules of thumb that are to be adhered to such as
to control the cause instead of worker, hazard elimination instead of reduce hazard exposure,
control under permissible exposure limit, control as low as practicable and lastly is the
implementation of personnel protective equipment (PPE).
 1.1 Report objective

The objective of this report is to identify the safety and health hazard at the maintenance
workshop section, to evaluate the risk and potential risk and to prioritize the risk rank and to
recommend the control measures with the objective of eliminating or reducing the risk
exposure at the place of work.

1.2 Methods used

This objective can be achieved through the assessment activity of identification of

hazard from the work activities that being carried out, facilities and tools used at the place of
work and the working environment. The risk will be assessed by using established risk matrix
to prioritize it according to its criticality. Finally, the highest hazard / risk identified will be
controlled accordingly by using the established 6 hierarchy of control method.

1.3 Result obtained

There are several hazards that have been identified during the HIRARC process. There
are 6 significant hazard has been identified in this specific activity, which out of 6 hazard, 4
of them are safety hazard and the other 2 are health hazard.

1.4 Suggestion and control measures recommended

As the hazard in maintenance in various working environment and condition / act being
identified, the corrective and preventive action has to be implemented to ensure the hazard is
eliminated or reduced so as to ensure the employees is not affected by these hazard. The
commonly known control measures will be used as guidance in ensuring proper control of the
hazards. The control measures as per hierarchy are Elimination, Substitution, Isolation,
Engineering control, Administrative control and Personal Protective Equipment (PPE).

2.0 INTRODUCTION
 2.1 Company Profile

Konsortium PD Sdn Bhd was established in 2001, Konsortium PD Sdn Bhd is a

Road Transportation logistics company consisting for Shell hauliers. The company
transports industrial petroleum oil diesel B7, U95, U97, E5. The company HQ based in
1 - 3, Jalan Lukut Bestari 1, Medan Lukut Bestari, 71010 Lukut, Port Dickson,Negeri
Sembilan, Malaysia. Knows as an exemplary haulier in the shell community, KPD
distribution fleet KPD PD operate to 56 shift covering Negeri Sembilan, Melaka,
Segamat, Muar, Batu Pahat, KPD KVDT operate to 65 shift covering Kuala Lumpur,
Selangor, Teluk Intan, Pantai remis, Ipoh and Sepang. Wesport cover central Pahang
South Selangor.

KPD has a strong commitment towards Health, Safety, Security and

Environment (HSSE) with strong Safety & Health community ER team, fire and rescue
team, spill and prevention. Managing Director and safety group manager cover KPD
PD, Wesport, KVDT aspects of HSSE with numerous systems and processes
throughout our operations

2.2 Organizational chart

 Diagram 1: Organizational charts in KPD PD SDN BHD

2.3 Number of worker

The total number of employee of Konsortium PD Sdn Bhd is over 300 drivers 90 staffs and
40 in – house contractors.

2.4 Activities

The main activities at the Konsortium PD Sdn Bhd are:

 Distribution
 Supplier petroleum product
 Vehicle maintenance
 Operation customer service

2.5 Overall work process

 The entire work process of the Konsortium PD Sdn Bhd is as illustrated below. Its starts with
Shell Operation received the order by customer place order online and contact shell customer service
followed by KPD Operation received the order from shell operation and divide the order for driver to
delivery. After that, inspection truck Rota A for daily and weekly inspect, Rota B for monthly inspect
before vehicle moving for delivery. After inspect if truck has breakdown immediately sent to vehicle
maintenance to repair. After that, loading product at refineries as customer order. Delivering to the
stations followed Journey Management Plan for more efficient and on time. After arrived at stations
unloading process is discharge process it is process to fill up that station.

2.6 Specific work process

There are five major change new tire process. These five are jack up truck, loose lug nuts,
remove wheel truck, install new tire, replace lug nuts. . (Flowchart 2)

Flowchart 2
i

Remove
Jack up Loose Install Replace
wheel
truck lug nuts new tire lug nuts
truck

Jack up truck

Jack up truck using hydraulic floor jack to stand up truck and double check it strong
enough. It is easy to replace new tire and pull out wheel from truck

ii Loose lug nuts

Use air wrenches to loose lug nuts from hub-cap

iii Remove wheel truck

After that, can remove wheel truck from hub-cap and keep tire under truck

iv Install new tire

Place new tire and careful positioning it over the wheel studs
v Replace lug nuts
 Begin replacing the nuts by air wrenches them back into place

3.0 Objectives

The objective of this workplace report is to conduct comprehensive study, analyzing

and provide recommendations and solutions to the identified issues arises in the activities

carried out in the organization specifically in the warehouse section.

Ultimately, there are three main objectives of this report such as follows :

A. To identify related hazard

i. To adhere to all related legal requirement under the related act such as OSHA 1994

ii. Implementation of good management systems such as OHSAS 18001 or MS1722.

B. To prioritize the risk through the risk assessment

i. To assess and evaluate the risk or potential risk associated to the work activity.

ii. To assist the organization in prioritizing the risks whenever making decisions to

control the hazards based on the facts and priority.

C. To provide solution on suitable ways to control the hazards.

i. To recommend the organization on most systematic and effective ways in managing

hazards.

ii. To provide best and suitable or practicable recommendation control measures to

mitigate or minimize the associated risks.

iii. To review effectiveness of the risk control measures.

 iv. As a continual improvement processes in managing the hazard and risk at

workplace.

4.0 Methodology

4.1 Three methods used in hazard identification process

There are many ways of identifying hazards. Basically, a few methods have been applied in
identifying the hazards. The methods used are as follows:
a. Workplace observation
b. Record analysis

i) Workplace observation
Workplace observation has been conducted by identifying and dedicating a target group
or activity at certain period of time. As an example, whenever the Safety, Health,
Environmental committee thinks that the working environment of a certain place of work are
not safe or healthy, they may direct an individual or group of people to observe the respective
working area. During the observation, the findings can be communicated directly to the
employee, supervisor for immediate improvement. Photo shall be taken to documented as
workplace inspection record. The workplace observation can be conducted constantly without
specific time. The findings will be communicated during daily meeting and through media
social group (whatsapp).

As for the workplace inspection, it is carried out at least once in every three months
once as stipulated under the Occupational Safety Health (Safety and Health Committee)
regulations 1996. Unlike workplace observation, workplace inspection is a well-planned
program with established committee members.

ii) Document review

Secondly, document review is a form of auditing whereby, the related document will be
checked. During document review, it may or may not inclusive of the established procedure
checking. As an organization that has been certified with OHSAS 18001:2007, we are
mandatory required to check the establish management system procedure and are subject for
a continual improvement process requirements. Partly, we also to conduct an internal auditing
and to the management system that has been established and implemented so as to ensure
comply to all legal requirements.

4.2 Explain methods of risk assessment (risk estimation and risk evaluation)
The methods of risk assessment, risk estimation and risk evaluation are based on the;
 Frequency of similar activity that is being carried out.
 Length of exposure to the hazards.
 Accident trend and record.

4.3 Matrix used, explanation of likelihood and severity and decision for action
Definition of risk is a combination of the likelihood of an occurrence of hazardous
event with specified period and circumstances and the severity of injury or damage to the
health of people, property, environment or any combination of these caused by the event. In
order to evaluate the risk, use of probability / likelihood table and severity / consequences
table has been used as a guideline to determine the risk value.

Below is the probability / likelihood table (Table A) and severity / consequences table (Table
B) that is used as reference;
LIKELIHOOD RATING TABLE

LIKELIHOOD (L) EXAMPLE RATING

Most likely The most likely result of the 5

hazard/event being realized
Possible Has a good chance of 4
occurring and is not unusual
Conceivable Might be occur at some time 3
in future
Remote Has not been known to occur 2
after many years
Inconceivable Is practically impossible and 1
has never occurred

SEVERITY RATING TABLE

SEVERITY EXAMPLE RATING

Catastrophic Numerous fatalities, irrecoverable 5

property damage and productivity

Fatal Approximately one single fatality 4

major property damage if hazard
realized
Serious Non – fatal injury, permanent 3
disability

Minor Disabling but no permanent injury 2

Negligible Minor abrasions, bruises, cuts, first 1

aid type injury
The risk ranking is formula calculation to determine the risk value.
Risk (R) = Probability (P) x Severity (S).
Below are the examples to determine the risk calculation and risk rank;

Safety Hazard
Risk = Probability x Severity
=4x4
= 16
Health Hazard
Risk = Probability x Severity
=4x4
= 16

Likelihoo 1 2 3 4 5
d (L)
5 5 10 15 20 25

4 4 8 12 16 20

3 3 6 9 12 15

2 2 4 6 8 10
1 1 2 3 4 5
 Table C: Quantitative Matrix

Based on the above risk matrix assessment table, risk level can be divided into three stages as

shown in Table D

Score Risk Rank

1–4 Low

5 – 12 Medium

13 - 15 High

Table D: Risk Ranking

All hazards that are ranked as HIGH and MEDIUM will be control to reduce its risk to LOW.

Based on the internal procedure, (as shown in below table), details of the action to be taken to

reduce the risk are as per tabulation. Basically, our course of action to control the risk is

based on the Table E.

15 - 25 HIGH A HIGH risk requires immediate

action to control the hazard as
detailed in the hierarchy of control.
Action taken must be documented
on the risk assessment form
 including date for completion.
5 - 12 MEDIUM A MEDIUM risk requires a planned
approach to controlling the hazard
and applies temporary measure if
required. Action taken must be
documented on the risk assessment
form including date for completion.
1-4 LOW A risk identified as LOW may be
considered as acceptable and
further reduction may not
necessary. However, if the risk can
be resolved quickly and efficiently,
control measure should be
implemented and recorded.

5.0 Result and Discussion

5.1 List and tabulate 6 hazards according to criticality of the risk.

 A. Safety Hazard (4 safety hazard)

No Safety Hazard Risk Rank

1 Truck toppled High risk

2 Falling loads Low risk

3 Physical injuries Low risk

4 Slippery floor (spillage oil) Low risk

B. Health hazard (2 health hazard)

No Health Hazard Risk Rank

1 Vibration hazard Medium risk
2 Excessive noise Medium risk

5.2 List hazard based on their rating

HIRARC FORM
Company: Konsortium PD Sdn Bhd Conducted by: Muhammad Iqram
Process/Location: Change tyre / Maintenance Bin Sulaiman
workshop (EHS Trainee)
 Approved by:

th
Date: 12th February
Date: 12 February 2019 Review Date: Next Review
Date:

No Work process Hazard Potential risk Existing Likeli Sever Risk Recommendation
control hoo ity
d
1 Jack up truck Truck Fatality N/A 4 4 16  Give awareness and
toppled High training to workers
(S)  Provide safe work
procedure
 Keep monitoring
and inspection
2 Loose lug nuts Vibration Full arm Safety gloves 4 3 12  Provide leather
using hand tools due power vibration mediu glove
machine hand tool Briefing m  Introduce anti-
(H) before start vibration glove
work  Keep monitoring
and observation
 Provide safe work
procedure
 Provide job
rotation
Excessive Temporary Earmuff 4 3 12  Noise monitoring 6
noise hearing loss Mediu months
(H) Shift work m  Provide earplug
 Provide training
Briefing and awareness
before start
work
Physical Swollen Safety gloves 2 2 4  Provide leather
injuries hand Low gloves
(S) Briefing  Keep monitoring
before start and observation
work  Provide safe work
procedure
3 Remove wheel falling load Body Safety shoes 2 2 4  Provide continuous
truck (S) fracture. Low awareness and
(due to Safe work training
falling load) procedure  Continuous
monitoring
Briefing
before start
work
4 Install new tire Slipery floor Tempory Safety shoes 1 2 2  Provide grib shoes
(spillage oil) born Low  Provide safety
(S) fracture operating
procedure
 Keep monitoring
 5.3 Rationalize your choice for the most critical hazard (1 safety and 1 health)

There are two most critical hazards that have been assessed during the hazard

identification, risk assessment and risk control activity that has been carried out.

i. Critical safety hazard

Based on the risk assessments that were conducted in the vehicle service, the most critical
safety hazard is can fall and damage property.The likelihood is 4 rated , which are likely to
occur. Based on the observation, we found that most of the can fall and damage to property
while jack up the truck. The contribution factors of this type of misconduct may varies from
the job requirements, lack of training, tendency of not to follow and abide to the rules and
procedure and also employee behavioral issue.

For severity, it is rated 4 because the damage can be very expensive because of the truck
cost. The component truck are very costly due to the limitation of its resources and
development cost, production processes complication etc. Furthermore, an internal and
external factor in business and operational terms and conditions becoming tougher that makes
incidences involving the servicing is not tolerable. The incidences occurrence may delay the
repair process and customer product to delivery.

Based on the formula to rank the risk, [Risk = Probability X Severity], the risk value is 12.
This risk level is ranked as HIGH:
* According to Konsortiun PD Sdn Bhd internal safety and health procedure, all hazards that
is ranked as high and medium, corrective action shall be taken to lower the risk.

ii. Critical health hazard

The assessment was also conducted to identify one critical health hazard. It was found
that using air wrenches heavy vibration cause carpal tunnel syndrome to the workers. This is
as a result long period contact with vibration. In addition, based on the observation, it is
found that the contact to the hand can cause wrong position posture. Furthermore, based on
the accident record, it was found few cases that reported due to emotional distress. Therefore,
as for likelihood, it is rated 4 based on justification stated. As for severity, it is rated 3 as it
posed chronic hazards. The workers may have great tendency to have carpal tunnel
syndrome due to exposure to vibration
 Based on the formula to rank the risk, [Risk = Probability X Severity], the risk value is

15. This risk level is ranked as MEDIUM.

* According to Konsortium PD Sdn Bhd internal safety and health procedure, all hazards that

is ranked as high and medium, corrective action shall be taken to lower the risk.

5.4 Explain impact of the most critical safety and health risks identified to the
organization

i. Impact of the most critical safety hazard.

Manual hand tool is the main used while repair truck engine in the vehicle service. It was
the requirement for maintenance department
 There is possibility to substitute it with other. However, the effectiveness and its efficiency
to the productivity are doubtful. With the use of manual hand tool, repair can be easily and
reduce breakdown of the truck. On the other hand, an employee is also an important asset in
this industry. Hence, should the worker being operated in unsafe manner, in this scenario that
would lead to accident causing major injuries or fatality, these two factors may contribute to
huge loss to the organization.

The employee development, training and awareness as to ensure the employee are able to
perform the task at required and acceptable skill will need the organization to reinvest not
only with money, but time as well.

Workplaces that have lot of accident will also lowering the employee morale and
motivations. The employee may also think that the organization did not seriously taking care
of their safety, health and welfare at place of work and will cause unsecured feeling among
the employee. Subsequently, their psychologically towards productivity contribution may
also be affected. Finally, these situations will also be affecting the organization as profit
making will become lesser.

ii. Impact of the most critical health hazard.

Using power hand tool for long period may cause have to carpal tunnel syndrome due to
exposure to vibration

. If it is not well taken care of, the organization will be dealing with higher medical record
due to exposure to chronic health issue that is facing by the related group of employees.

Carpal tunnel syndrome may lead to pain and numbness because of heavy vibration while
using power hand tool. Frequent medical leave may be taken by the involved employee as
they are not fit to perform the similar task. In term of productivity, the company will be at the
losing side for lesser productivity translated into lesser profit making.
The organization will also have to bear most cost on the correction action that need to be

taken with regards to this condition or hazards. The organization will need to hire additional

manpower, provide unnecessary or additional training scheme, losing skillful employee, pay

6.0 Recommendation

6.1 Explain detail of the proposed control measures for the most critical SAFETY
HAZARD.

The critical safety hazard as briefly explained in previous chapter, would post great impact
and it is not tolerable. Prompt action has to be taken and risks control principals will be a
guideline and tools in taking the most appropriate control measures. In order to solve this
issue, the common hierarchy of control will be used for systematic and effective control
measures such as follows;

a. Eliminate Not applicable

b. Substitute Not applicable
c. Isolate Not applicable
d.Engineering Not applicable
control
e. Admin control i. Provide continuous awareness and training
ii. Provide safe operating procedure
iii. Keep monitoring and inspection
f. PPE Not applicable

A. Eliminate
Not applicable

B. Substitute
Not applicable

C. Isolate
Not applicable

D. Engineering control
Not applicable

E. Administrative control
i. Provide continuous awareness and training.
ii. Provide safety operating procedure to handling the jack floor
iii. Constant monitoring and inspection handle jack up the truck

F. Personal Protective Equipment

Not applicable
6.2 Explain detail of the proposed control measures (preventive and corrective) for
the most critical HEALTH HAZARD.

a. Eliminate Not applicable

b. Substitute i. Substitute power hand tool with low vibration
c. Isolate Not applicable
d.Engineering Not applicable
control
e. Admin control i. Job rotation
ii. Training and awareness
iii. Introduce Stretching and Exercise every morning before start work
iv. Intermittent rest every few hours

f. PPE i. Provide anti-vibration gloves

A. Eliminate
Not applicable

B. Substitute

i. Currently, the hand power tool is heavy vibration to handle. Change the hand tools better

and less vibration.

C. Isolate
Not applicable

D. Engineering control

Not applicable

E. Admin control

i Introduce job rotation system to avoid the workers exposure vibration for long period

ii Continuous training and awareness are also needed so that workers can understand the

hazard that they exposed to so they will aware to reasonably take care of their own safety as

well.

iii Introduce stretching and exercise every morning around 15-30 minutes before start

working.

iv Intermittent rest every few hours for those who operate air wrenches may also help to

reduce the exposure of having the risks of CTS (carpal tunnel syndrome)

F. Personal Protective Equipment

i Introduce anti-vibration glove to reduce vibration

6.3 Explain the proposed review program on the effectiveness on the

proposed control measures in subsection 6.1 and 6.2.

The importance review program and its effectiveness will determine whether the
management system cycle is efficient or not. The cycle of the management system as per
established model system illustrated and guided the organization sufficiently. Common
process flow in good management system process includes few stages as follow;

Planning
To determine the area to assess the HIRARC and to type of activity to be assessed etc.

Implementation
Conducting assessment, hazard identification, assessing the risk level and implement risk
control measures.

Checking
To conduct an inspection periodically. This can be done according to our plan based on the
criticality and needs. It can be performed every weeks, month, quarterly, half yearly or even
once in a year. The observation also can be conducted as to check and verify the status. The
checking also may include internal audit to check on the gaps between the planning and
implementation stage.

Review
At this point, most of the implementation should already be implemented. Through the
checking stage, discrepancies can be detected, gap can be found, failure can be identified.
At this stage, there are several questions can be asked such as;

i. Have the control measures effectively solved the problem?

ii. If the control measures did not effectively solve the issue, what are other options?
iii. Are there any other control measures should be taken to control the hazard?

The review program shall also include but not limited to;

i. Safety, Health Environmental department meeting can be used as one of the most
effective platform as it is conducted once in every three month or can also be held as a when
required. All members can assist to give feedback on specific matters that are required for
immediately review.

ii. Tracking of documents so as to ensure the proposed control measures implementation

is recorded. This would help the tracking on which of the proposal has been implemented.
Should there is any available control measures that are yet to be implemented, the next
review shall consider of implementing it. In case all the proposed control measures in 6.1 and
6.2 has been implemented, yet it is not effective, then new assessment shall be taken place to
revise the control measures.

iii. Lacking of information, instruction and training provided to the employee are also the
elements to be reviewed as well. These elements are important on following areas;
a) Understanding on the principles of safety and health such as control measures
hierarchy, hazards identification etc.
b) Safety procedures that has been / will be established.
c) Proper PPE usage.

iv. Document review can be used as a process to register or update any shortage in
certain procedures etc. Adequate procedures contents, user friendly and simple can be very
useful to guide employee in their course of action.

Continual improvement
All the proposed program review is a continual improvement process and this cycle will be
an ongoing process.

6.4 Discuss the benefit of the recommendations in subsection 6.1 and 6.2.

A. Organization
i. Management will have a good and systematic safety and health management
system in terms of managing the hazards and risk
ii. Number of incident and accident will be decreasing should the safety and health
of the employee are well taken care off.
iii. Number of medical leave relates to the employee poor health condition becoming
lesser thus cost saving can be made as the visiting record to doctor become lesser
as well. The insurance premium utilization will also be decreasing.
 iv. The company can maintain their image and could be one of contribution factor to
earn continuation of concession.

B. Employee
i. Employee awareness on safety and health at place of work is increasing.
ii. Employee will be more responsible towards their action that may affect safety and
health on themselves as well as others.
iii. Employee will feel secure, safe therefore will contribute to organization by
supporting its vision to be most preferred medical supplies company in Malaysia.

7.0 References / Sources

Book resources

1. (1994). Occupational Safety and Health Act 1994 and Regulations. Malaysia.

Website resources

1. (2013). Konsortium PD Sdn Bhd. Retrieved from http://www.kpdhaulage.com.my/

 2. Mayo Clinic Staff. (2017, March 30). Carpal Tunnel Syndrome. Retrieved from
https://www.mayoclinic.org/diseases-conditions/carpal-tunnel-syndrome/symptoms-
causes/syc-20355603

3. (1996). Hand and Power Tools Safety. Retrieved from

https://www.safetyinfo.com/hand-and-power-tool-safety-index/

8.0 Attachment / Appendix

1. Attachment 1 - Safety, Health, Environment organization chart

Department

Stuart Cheok Kem Koon

Transport Manager

Suresh Raj A/L Subramaniam

Road Transport Safety Officer

(RTSO)
 Transport Assistant

Darshini

2. Attachment 2 - main office and HQ Konsortium PD Sdn Bhd

3. Attachment 3 - vehicle maintenance workshop