UNIVERSITI TEKNIKAL MALAYSIA MELAKA
A STUDY OF SAFETY AND HEALTH AWARENESS AND
NOISE ASSESSMENT AT STAMPING DIE COMPANY
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Management) (Hons.)
by
SITI NUR ADIBAH BINTI ITHNIN
B051010249
890515-09-5190
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: A St udy of Safet y and Healt h Awareness and Noise Assessment at St amping Die Company
SESI PENGAJIAN: 2012/ 2013 Semest er 2
Saya
SITI NUR ADIBAH BINTI ITHNIN
mengaku membenarkan Laporan PSM ini disimpan di Perpust akaan Universit i Teknikal Malaysia Melaka (UTeM) dengan syarat -syarat kegunaan sepert i berikut :
1. Laporan PSM adalah hak milik Universit i Teknikal Malaysia Melaka dan penulis. 2. Perpust akaan Universit i Teknikal Malaysia Melaka dibenarkan membuat salinan
unt uk t uj uan pengaj ian sahaj a dengan izin penulis.
3. Perpust akaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pert ukaran ant ara inst it usi pengaj ian t inggi.
4. **Sila t andakan (
√
)SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarj ah keselamat an at au kepent ingan Malaysiasebagaimana yang t ermakt ub dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang t elah dit ent ukan oleh organisasi/ badan di mana penyelidikan dij alankan)
Alamat Tet ap:
1692, Lorong Kempas 7/ 1,
Taman Kempas,
Sungai Pet ani, Kedah
Tarikh: _________________________
Disahkan oleh:
Cop Rasmi:
Tarikh: _______________________
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of
UTeM as a partial fulfillment of the requirements for the degree of Bachelor
of Manufacturing Engineering (Manufacturing Management) (Hons.).The
members of the supervisory committee are as follow:
………
(Principal Supervisor)
DECLARATION
I hereby, declared this report entitled “A Study of Safety and Health Awareness
and Noise Assessment at Stamping Die Company” is the results of my own
research except as cited in references.
Signature
:
……….
Author’s Name
:
Siti Nur Adibah Binti Ithnin
Date
:
………
ABSTRAK
Laporan ini disediakan untuk menerangkan kajian kesedaran keselamatan dan
kesihatan di kalangan pekerja dan penilaian bunyi di syarikat acuan dan alat tekan.
Kajian ini meliputi Akta Keselamatan & Kesihatan Pekerjaan (OSHA), OSHA 1994,
bahaya, pendedahan bunyi bising dan pencegahan bunyi di Miyazu Malaysia Sdn
Bhd (MMSB). Kaji selidik dijalankan mengenai tahap kesedaran pekerja kepada
Kesihatan dan Keselamatan di persekitaran tempat kerja.Kajian ini juga akan
mengkaji tentang tahap bunyi yang dihasilkan mesin merujuk kepada piawai OSHA.
Data yang telah diperolehi daripada beberapa kaedah termasuk pemerhatian,
temuramah orang yang berkenaan, kaji selidik kepada pekerja di kawasan yang
dinyatakan dan pengukuran teknikal. Data akan dikumpul menggunakan peralatan
berkaitan seperti Digital Sound Level Meter. Tahap standard piawai pendedahan
bunyi di kawasan yang dinyatakan dikaji dan dibandingkan dengan data yang
diperolehi dalam keputusan kajian ini.Keputusan yang ditunjukkan akan
dipertingkatkan dengan beberapa cadangan untuk mengurangkan atau memperbaiki
masalah.
ABSTRACT
This report is provided to explain a study of safety and health awareness among
worker and noise assessment at stamping die company. This study covers the
Occupational Safety and Health Administration (OSHA), OSHA 1994, hazard, noise
exposure and noise improvement at Miyazu Malaysia Sdn Bhd (MMSB). This study
carried out survey regarding to level of awareness among worker to Safety and
Health in the workplace.This study also about noise level produces by machine
compare to OSHA standard. The data was obtained from several methodologies
includes observation, interview the authorized person, questionaire among worker in
specified area and technical measurement. The data were collected by the related
equipment such as Digital Sound Level Meter. The standard level of exposure on the
focused area studied and compared with current value that obtained in this study.The
result show will be improved by some recommedation to minimized or eliminated
the problem.
DEDICATION
To my beloved family thanks for continuous support to me in performing this
difficult task, and the journey does not end here.
To my supervisor, Mr. Al Amin bin Mohamed Sultan and Co- Supervisor, Mr. Mohd
Shahrizan bin Othman for being receptive and critical, and challenging me to be a
better student.
To all course mate, for always support me, and also to my entire friend, for their
sacrifice, encouragement, and support towards project accomplishment.
Thank You
ACKNOWLEDGEMENT
Utmost gratefulness to The Almighty ALLAH SWT for the abundant blessing and
favours for me to accomplished the research Projek Sarjana Muda.
I would like to extend my warmest gratitude to my supervisor and my co- supervisor,
Mr. Al Amin bin Mohamed Sultan and Mr. Mohd Shahrizan bin Othman for their
excellent supervision, invaluable guidance, advice trust, constant help, support,
encouragement and assistance towards me throughout this project.
I would also like to thank Miyazu Malaysia Sdn Bhd, and their staff as they provided
me to make data collection, and always shows their sincere kindness in helping and
gave me useful information.
Ina addition, I would like to thank my family whose endless encouragement gave me
the added strength and inspiration to carry out this project to the best of my ability.
At the same time, I would like to thank my friends and course mate for their
constructive comments throughout the accomplishment of this project.
TABLE OF CONTENT
Abstrak
i
Abstract
ii
Dedication
iii
Acknowledgment
iv
Table of Content
v
List of Tables
ix
List of Figures
x
List Abbreviations, Symbols and Nomenclatures
xii
CHAPTER 1: INTRODUCTION
1
1.1
Background of study
1
1.2
Problem Statement
2
1.3
Objective
3
1.4
Scope of project
4
1.5
Importance of Study
4
1.6
Report Outline
5
1.7
Summary
5
CHAPTER 2: LITERATURE REVIEW
6
2.1
Occupational Safety and Health Administration (OSHA)
6
2.1.1 Objective of OSHA
8
2.1.2 Occupational Safety and Health Act 1994
8
2.1.3 Scope of OSHA 1994
10
2.1.4 Objective of OSHA 1994
10
2.1.5 Principles of OSHA 1994
10
2.2
OSHA Issues in Manufacturing Company
11
2.3
Hazards in Workplace
12
2.3.1 Safety and Health Hazard
13
2.4
Noise Hazard
13
2.4.1 Definition of Noise
14
2.4.2 Noise Exposure
15
2.4.3 Noise Level Equipment
18
2.5
Noise Prevention
19
2.6
Previous Case Study Noise Exposure
24
2.7
Summary
28
CHAPTER 3: METHODOLOGY
29
3.1
Project Overview
29
3.1.1 Process Flow Chart
30
3.2
Methodology
31
3.3
Primary Data
31
3.3.1 Interview
32
3.3.2 Observation
32
3.3.3 Questionnaire
32
3.4
Secondary Data
33
3.5
Data Collection
33
3.5.1 Design of Questionnaire
34
3.5.2 Design of Interview
36
3.5.3 Noise Level Measurement
37
3.6
Data analysis
39
3.6.1 Statistical Method
39
3.7
Suggestion and Recommendation
40
3.8
Company Background
41
3.8.1 General Information
42
3.9
Gantt Chart
43
3.10
Summary
44
CHAPTER 4: RESULT & DISCUSSION
45
4.1
Introduction to Data Collection
45
4.2
Results and Data Analysis of Questionnaire
46
4.2.1 Personal Information
46
4.2.1.1 Gender
46
4.2.1.2 Working Experience
47
4.2.1.3 Working Hours
47
4.2.1.4 Types of Risks
48
4.2.2 Work Environment Issues
49
4.2.2.1 Work Environment and Noise Exposure
49
4.2.2.2 Dust and Lighting
50
4.2.2.3 Personal Protective Equipment
51
4.2.2.4 Health Quality and Accident
52
4.2.2.5 Health Screening
53
4.2.3 Safety and Health Awareness
54
4.2.3.1 Safety and Health Quality
54
4.2.3.2 Level of Safety and Health Policy
54
4.2.3.3 Safety Exposure and Safety Awareness
55
4.2.3.4 Occupational Safety and Health Act (OSHA)
56
4.2.3.5 Safety Instruction and Safety Campaign
56
4.2.3.6 Health Care by Employer
57
4.2.3.7 Social Security Organization (SOCSO)
58
4.2.3.8 OSHA Information
58
4.3
Result of Interview Session
59
4.4
Result of Observation
62
4.5
Result and Data Analysis of Noise Assessment
64
4.6
Discussion
72
4.6.1 Level of Awareness OSHA
72
4.6.2 Work Environment and Health Issues
74
4.6.3 Noise Assessment
75
4.7
Suggestion of Safety and Health Issues
78
4.8
Suggestion of Noise Improvement
79
4.8.1 Hearing Protection
79
4.8.2 Enforcement by the Administration
79
4.8.3 Machine Improvement
82
CHAPTER 5: CONCLUSION & RECOMMENDATION
83
5.1
Conclusion
83
5.2
Recommendation
84
REFERENCES
85
APPENDICES
86
LIST OF TABLES
2.1
Difference between FMA 1967 with OSHA 1994
9
2.2
OSHA’s Permissible Noise Exposure
16
2.3
Some commonly used engineering controls
20
3.1
Step in Designing Questionnaire
34
3.2
Types of Information
35
3.3
Gantt Chart
43
4.1
Types of Risks Percentages
48
4.2
Interview Session Result
60
4.3
Findings of Observation
62
4.4(a)
Average Noise Level for Day 1
65
4.4(b)
Average and Variance for Each Machine
65
4.4(c)
Summary of ANOVA Result
65
4.5(a)
Average Noise Level for Day 2
66
4.5(b)
Average and Variance for Each Machine
66
4.5(c)
Summary of ANOVA Result
67
4.6
T-test Result
67
4.7
F-test Result
68
4.8
Part 1 (Noise Comfortable)
69
4.9
Part 2 ( Noise Level Awareness and PPE)
70
4.10(a) Part 3 (PPE)
70
4.10(b) Part 3 (PPE)
71
4.10(c) Part 3 (PPE)
71
4.11
Percentage every needs aspects of Safety and Health
72
LIST OF FIGURES
2.1
Elements: Occupational Health
7
2.2
Typical Noise Levels in Manufacturing Sector
17
2.3
A modern sound level meter
18
2.4
A noise dosimeter
19
2.5
Sound Curtain or Sound Blankets
21
2.6
Composite Foam
21
2.7
Hearing Protection Devices
23
3.1
Process Flow Chart
30
3.2
Specifications Digital Sound Level Meter Model 407730
37
3.3
Noise Measurement Mapping Diagram
38
4.1
The Types of Data Collection
45
4.2
The Distribution by Gender
46
4.3
The Distribution by Working Experience
47
4.4
The Distribution by Working Hours
47
4.5
The Distribution by Types of Risks
48
4.6
Comfort with Work Environment Percentages
49
4.7
Comfort with Noise Exposure Percentages
50
4.8
Comfort with Dust Percentages
50
4.9
Comfort with Lighting Percentages
51
4.10
Wearing PPE during work Percentages
51
4.11
Health Quality Percentages
52
4.12
Accident during work Percentages
52
4.13
Health Screening Percentages
53
4.14
Safety and Health Policy Percentages
54
4.15
Level of Safety and Health Policy Percentages
54
4.16
Level of Safety and Health Policy Percentages
55
4.17
OSHA Percentages
56
4.18
Safety Instruction Percentages
56
4.19
Health Care by Employer Percentages
57
4.20
SOCSO Percentages
58
4.21
OSHA Information Percentages
58
4.22
Plant Machinery Layout
64
4.23
Graphical Comparison of Noise Level between Day 1 and Day 2
69
4.24
Level of Awareness Diagram
73
4.25
Noise Mapping Layout
79
4.26
Noise Mapping Layout with Hearing Protection
81
4.27
Sample of Silencers
82
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
OSHA
-
Occupational Safety and Health Administration
PPE
-
Personal Protection Equipment
DOSH
-
Department Occupational Safety and Health
FMA
-
Factory and Machinery Act
WHO
-
World Health Organization
ISO
-
International Organization for Standardization
TWA
-
Time weighted average
ANSI
-
American National Standard Institute
PSM
-
Projek Sarjana Muda
MMSB
-
Miyazu Malaysia Sdn Bhd
ANOVA
-
Analysis of Variance
6 This chapter describes the introduction section of the report. It contains the problem
statement, objectives, importance of study and scope. This chapter also describes
background of study that related to the problem statement.
1.1
Background of study
Working workplace must be safe and comfort for all workers to work. A good
working environment will increases productivity and efficiency the company.
Sanjeev (2005) defines a safety working environment is the workplace has been
assessed for hazards and the hazards are eliminated or controls have been
implemented so that the company is able to operate safely.
A hazard is a source or potential source of human injury, ill health or disease
(Comcare, 2005). Hazard also can be defined such as anything will cause to injury or
ill health at workplace. Some hazards are easy to identify and obvious but others are
not for example, exposure to noise, poor lightning, chemicals and etc. All worker
need to be aware of the issues that will be effect on their health and safety at the
workplace. In other hand, the worker have to work in good environment where risk
to their safety and health are properly controlled.
INTRODUCTION
7 However, worker and employee have a legal responsible to look after safety and
health at workplace. Safety and health management system and programs are
designed with the purpose of ensuring the safety, health and welfare of person at
work and protection to other people from hazards to safety and health arising from
the activities of person at work.
The sound is also play an important part in our environmental especially in the
workplace area. The unwanted sound will become a noise to human hearing and
effect the human peacefulness. The high noise can cause human to lose their hearing
ability that is very important in human life. In the short term, the noise did not bring
any side effect to us but in the long term it can possibly hurt our hearing (Ahmad,
2008).
Because of that, this study was conducted to identify the level of awareness worker
about Occupational Safety and Health Administration (OSHA) regarding to hazard at
workplace. Besides, noise level exposures were access in order to reduce unwanted
sound in the industry. This study is done in the working area at Miyazu Malaysia Sdn
Bhd (MMSB), which is one of the parts of stamping die industry.
1.2
Problem Statement
Safety and Health issues are important in industries sector. Employer has responsible
to ensure their worker comfort and safe during work. Industries selected for this
study involved manufacturing sector which include stamping die, plastic mould,
module assembly, engineering services and production services. This company is
required to adhere to the requirements of the OSHA 1994 but it will be interesting to
know how the level of awareness worker about Occupational Safety and Health
Administration (OSHA) and hazards in stamping die workplace. In order to measure
the safety and health awareness among worker, it is importance to know condition of
8 Besides, worker of this company also exposed to noise but the stamping die areas
which exceed the OSHA standard is not identified. From that, it concern to know the
noise level in the specified area. In addition, worker of these company not wear any
Personal Protection Equipment (PPE) such as ear plug or ear muff were they are
exposed to noise during work. But, the PPE are provided.
1.3
Objectives
Three specific objectives have been simplified of this study. There are:
i) To assess the safety and health awareness among stamping die company
worker
ii) To analyze the noise level of machine refers to OSHA standard.
iii)To suggest the proper solution according to excessive noise level at stamping
die company
1.4
Scope of Project
This study was focused on the level of safety and health awareness worker at
workplace. Interview and questionnaire conducted to evaluate the level of awareness
regarding to OSHA and hazard during visit the company. A questionnaire consists 22
question have been prepared for 30 workers. Noise level at this company was
measured using Digital Sound Level Meter and collected for each machine at
Tooling Plant workplace. Based on the measurement, the most critical noise level is
identified and the proper solution suggested. Besides, noise mapping are used to
identify which area are most critical exposed to noise. A questionnaire also used in
noise assessment to find relationship between noise measurement and comfortable of
worker to noise at workplace. Then, some suggestions are proposed to reduce the
entire problem. In addition, this study focused on the work environment in Miyazu
9
1.5
Importance of Study
Regarding to this study, some benefits are give to the several parties such as
company employer, company worker and student. From employer view, this project
can help company to change their work environment based on safety and health
issues. Besides, the company can increase productivity, reduces injury and
comfortable of working environment. This study also may help the worker of
company to protect their health. The worker may change the workstation or
workplace while they do the job and it will give the comfortable for them. In
addition, this study also gives benefits to student to increase the ergonomic
knowledge based on real situation in manufacturing working area. The student also
exposed and applied the technical measurement based on hands on practice such as
noise level assessment.
1.6
Report Outline
Chapter 1 introduces the project which is including objectives, problem statement
and scope of project. In this chapter, it describes the study on working environment
which is related to Occupational Safety and Health Administration and hazard in the
company.
Chapter 2 describes the literature review on definition of OSHA and hazard and the
theoretical of health hazard, noise exposure, and definition of noise, method to
measure noise level and noise prevention method.
Chapter 3 represents the flow chart that carried out for the whole process of the
methodology such as in gathering information, collecting data and result evaluation
10 Chapter 4 represents development the data collection by using methods of
questionnaires, interview and observation. The results are analyzed and discussed by
constructed the measurement by using Microsoft Office Excel software. Besides, this
chapter discuss about suggestion for the improvement regarding to problem
statement.
Chapter 5 describes the conclusion and recommendation for future work.
1.7
Summary
This chapter is introducing the project background and the objective of the project. In
addition, the problem statement and scope of study also being clarify in order to limit
the range of this project conduct. The following chapters consist of the literature
11 This literature review explores the dominant themes includes study and research of
published materials like journals, thesis, case study, technical document, and online
library. Generally, the purpose of a review is to analyze critical segment of a
published body of knowledge through summary, classification and comparison of
prior research studies, reviews of literature, and theoretical articles. This chapter will
describe topics that related topic such as Occupational Safety and Health (OSHA),
definition of hazards and theory of health hazards. It also describes about noise
exposure and theory of noise such as definition of noise, noise equipment and
suggestion from previous study to prevent noise exposure.
2.1
Occupational Safety and Health Administration (OSHA)
Occupational safety and health is a major concern to many countries. A simple
definition of “ occupational safety and health (OSH)” in respect of a “ place of work”
or “ person at work” is , the “ state of being safe “ or “ the absence of factors that
could lead to accidents, injuries or interruptions to work” Occupational Safety and
Health Act (OSHA) is an act to make further provisions for securing the safety,
health and welfare of persons at work, for protecting others against risks to safety or
health in connection with the activities of persons at work, to establish the National
Council for Occupational Safety and Health, and for matters connected therewith
(Alwi, 2011,pp4).
LITERATURE REVIEW
12 Goetsch (2008,p13) describes the Occupational Safety and Health Administration
(OSHA) is the government’s administrative arm for the Occupational Safety and
Health (OSH Act).Formed in 1970, OSHA sets and revokes safety and health
standards, conduct inspections, investigates problem, issues citations, assesses
penalties, petitions the courts to take appropriate action against unsafe employers,
provides safety training, provides injury prevention consultation and maintains a
database of health and safety statistics.
According to Tatiya (2011) Occupational Safety and Health is traditional way to deal
with legislation, regulation, standards, safety guidelines, accident investigations and
safety inspections which provide information on causes of accidents amongst
particular groups of employees. There are four elements in Occupational Health.
Figure 2.1 shows the relationship between four elements of Occupational Health.
Cray and Mendeloff (2002) state OSHA does tens of thousands of inspections, and
imposes millions of dollars in penalties each year, but most workplaces are only
rarely visited, penalties are low relative to the cost of abating many workplace
hazards, and many injuries are unrelated to OSHA standards.
[image:23.612.206.448.412.649.2]13 Nowadays, environmental in industries can be a great danger to human if not
controlled properly. All the danger can be called hazards. According to the OSHA
rules and regulation, the environmental hazards can be minimized in order to protect
the worker and the general public. OSHA standards have required conditions or
adoption or use of one or more practices, methods or process to protect workers on
the job and to endure that worker have and use personal protective equipment (PPE)
when required for safety. The general duty of the OSH Act requires that employee
provide a workplace that free from hazards. (Geotsch, 2008, pp91)
2.1.1 Objective of OSHA
In order to prevent worker from injuries and illness, OSHA have their own objective
to achieve. The main objectives of OSHA are implemented in the company so that
employees can enjoy a better work place, safe and healthy by making and enforcing
laws and standards for safety and health at work. Cray and Mendeloff (2002) state
the mission of the Occupational Safety and Health Administration (OSHA) is to
“promote the safety and health of America’s working men and women” and part of
this mission is a goal to reduce workplace injuries. OSHA may impact workplace
injuries through one or more mechanisms. OSHA also allows the enforcement of
certain standards needed to protect workers. In addition, it seeks to prevent
employees from making works that may cause injury, illness and death.
2.1.2 Occupational Safety and Health Act 1994 (Malaysia)
According to DOSH (2006), Occupational Safety and Health Act (OSHA) were
enforced in Malaysia on 25th February 1994 with the intent to ensure safety, health
and welfare of all persons at all places of work. The Act also provides for a
consultative process at the policy level with the establishment of Nation Council for
Occupational Safety and Health. This consultative process extends to where safety
and health programs are implemented with both employers and employees
