CHAPTER V DATA ANALYSIS
5.1 Current Problem
During semester 1 of 2014 the number of incident in PT AFN increasing very significant compared with semester 1 of 2013. It becomes crucial issue on managerial level of PT AFN. Management worries it will affecting the production activity on PT AFN. Moreover, semester 1 is an entrance of the peak production activity.
5.1.1 Number of Incident
The data below shows the number of incident during semester 1 of 2014 increasing more than 50% compared with the number of incident during semester 1 of 2013.
NO AREA Jan Feb Mar Ap
r
May Jun Tota l
1 MOLDING 3 1 4
2 INJECTION MOLDING 3 2 4 3 12
3 SEWING 2 1 3 6
4 PAINTING 1 1 3 4 2 11
5 ASSEMBLY 3 1 2 9 10 7 32
6 FINAL ASSEMBLY AND
PACKAGING
5 7 3 17 24 44 100
7 QUALITY 1 1 1 3
8 WAREHOUSE 2 2
9 MAINTENANCE 2 1 1 4
10 OTHERS 1 1 1 3
TOTAL 9 16 11 33 46 62 177
Table 5. 1 Number of Incident Semester 1 2013
Total 4
12 6 11
32 100
3 2 4 3
Number of Injury Based on Area Semester 1 2013
MOLDING INJECTION MOLDING
SEWING PAINTING
ASSEMBLY FINAL ASSEMBLY AND PACKAGING
QUALITY WAREHOUSE
MAINTENANCE OTHERS
Figure 5. 1 Incident Number Chart Semester 1 2013
NO AREA Jan Feb Mar Apr May Jun Total
1 MOLDING 2 1 1 3 2 9
2 INJECTION MOLDING 4 2 1 6 8 4 25
3 SEWING 5 3 6 3 6 7 30
4 PAINTING 5 1 3 1 2 4 16
5 ASSEMBLY 4 10 7 6 13 5 45
6 FINAL ASSEMBLY
AND PACKAGING
16 14 17 19 27 43 136
7 QUALITY 2 2
8 WAREHOUSE 1 1
9 MAINTENANCE 2 2 1 1 1 7
10 OTHERS 2 1 2 1 6
41 34 34 41 61 66 277
Table 5. 2 Number of Injury Semester 1 2014
Total 9
25 30
16 45
136
2 1 7 6
Number of Injury Based on Area Semester 1 2014
MOLDING INJECTION MOLDING
SEWING PAINTING
ASSEMBLY FINAL ASSEMBLY AND PACKAGING
QUALITY WAREHOUSE
MAINTENANCE OTHERS
Figure 5. 2 Incident Number Chart Semester 1 2014
Based on the data above, in both years the highest number of incident happens in final assembly and packaging area. Based on initial observation, it happens because the number of machine on this area is high either the number of worker that work in this area.
5.1.2 Type of Injury
In order to know the cause of the incident, we have to know the type of the incident that happens during semester 1 of 2014. The company already classifies type of incident into several categories. The categories are made based on the cause and effect of the incident.
This study is focused on final assembly area, which has the highest number of incident. The data below is the type of incident that happens in final assembly and packaging area. As mentioned earlier, the type of incident already classified by X Inc. for their entire business unit. It means these types of incident also occur in other area in all X Inc. business units.
No Month
Cut, laceration, puncture,bruise Slip, trip, fall Crushed, pinched, struck by Chemical exposure (splash, eye irritation, dermatitis, rash) Lifting Repetitive motion Burn, scald Other
Total
1 January 10 3 2 1 16
2 February 8 2 3 1 14
3 March 8 2 5 2 17
4 April 11 3 3 2 19
5 May 15 5 3 1 3 27
6 June 19 3 9 4 7 1 43
TOTAL 71 0 15 26 0 7 14 3 136
Table 5. 3 Type of Incident in Final Assembly and Packaging Area Semester 1 2014
TOTAL 71
0
15
26
0
7
14
3
Type of Incident on Final Assembly and Packaging Area Semester 1 of 2014
Cut, laceration, puncture, bruise Slip, trip, fall
Crushed, pinched, struck by
Chemical exposure (splash, eye irritation, dermatitis, rash) Lifting
Repetitive motion Burn, scald Other
Figure 5. 3 Type of Incident on Final Assembly and Packaging Area Semester 1 of 2014
As mentioned above, the type of injury classified by the company based on the cause and effect of the incident. This classification applied in all business unit of X Inc. There are seven types of injury:
Cut, Laceration, Puncture, and Bruise is the type of injury that caused by sharp tool that used in cutting process. Sharp tools that causing this type of injury in final assembly area are scissors, trimmer, and seal cutter.
Usually, the effect of the incident is scratched, sliced, and bleeding.
Slip, Trip, and fall is the type of injury that caused by low-friction surface such as wet surface, trash on the floor, and so on. Usually this type of incident happens when the worker walking on the area the effect of this injury is bruised, and bleeding.
Crushed, pinched, and struck is the type of incident that caused by moving sharp tool such as pinching tool, pinning tool, and so on. The effect of this type of incident is bleeding.
Chemical exposure is the type of incident that caused by chemical material that used in the process. Chemical exposure sometimes difficult to detect because usually it happens after several period of time. The effect of this type of incident is skin illness.
Lifting is the incident that caused by lifting the material. It hard to detect because it happens after several time of period or cycle. The effect of this incident is occurs after long time of activity. The effect of this type of incident is cumulative trauma disorder of the body part.
Repetitive motion is the type of incident that caused by cumulative trauma disorder that happens inside the body. In final assembly and packaging area most of worker that got injury because of repetitive motion is the worker who work in assembly area. It happens because they assemble a small part, so they need big effort and energy to assemble.
Burn and scald is the type of incident that caused by hot surface and material. There are 3 levels of burn, burn level 1 is minor wound and the worst is burn level 3. In final assembly area, there is equipment that resulting hot surface; the first is oven to heat the doll’s head, and the second gluing machine that used to melt the glue. There is also hot material which is hot glue that resulted from gluing machine.
The rest of incident that does not recognize in X Inc. included in other.