A TRAINING FOR THE

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RISK MANAGEMENT FOR METALWORKING INDUSTRY
A TRAINING FOR THE METALWORKING INDUSTRY
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Table of Contents
We will introduce the following topics to you

• Background for Risk Assessment
• How to Conduct Risk Assessment
• Risk Assessment Team
• Hazard Identification
• Control Measures
• Evaluation of Risk Levels
• Maintenance of Risk Assessment
• Exercise

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Background for Risk Assessment
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Background for Risk Assessment
The WSH (Risk Management) Regulation was
introduced because

• Since 2000, incident rate maintained constant
  around 2.2 per 1,000,000 man-hour worked
• Gaps in WSH performance with other developed
  countries
• Target to halve the number of work-related
  fatalities to 2.5/100,000 workers by 2015

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Background for Risk Assessment
Incident Statistics from MOM (Singapore)
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Background for Risk Assessment
Fatality Rate Statistics of other countries
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Legal Requirements
Risk assessment is important because

• It is required by the law, e.g. Workplace
  Safety and Health (Risk Management) Regulations
• It helps the stakeholders to eliminate, reduce
  or mitigate hazards
• It keeps employees safe in their workplace

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Legal Requirements
The framework for the new Workplace Safety and
Health Act and its regulations is to

• Reduce risks at source
• Take greater industry ownership of WSH outcomes
  
• To prevent accidents through higher penalties
  for poor safety management

For effective control of risk, risk assessment
must be communicated to relevant parties.
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How to Conduct Risk Assessment
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Risk Assessment can be done by

• Establishing the risk assessment team
• Identifying all the hazards
• Identifying all the existing control measures
• Evaluating the risk levels
• Evaluating whether additional control measures
  are required

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Team Member
Risk Assessment Team consists of

• Team Leader
• Management Staff
• Process/Facility Engineer
• Technical Personnel
• Supervisors
• Production Operators
• Maintenance Staff
• Safety Manager/Executive

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Responsibilities
Employers shall

• Assign a competent person leading the risk
  assessment team
• Ensure that employees are aware of the risk
  assessment for their work
• Provide a register to record findings of risk
  assessment
• Inform all personnel involved about risks in
  the workplace and means to minimize / eliminate
  risks
• Ensure risk control measures are implemented at
  the end of risk assessment

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Responsibilities
Employers shall

• Keep the risk assessment record for inspection
  for at least 3 years and submit it to
  Commissioner for Workplace Safety and Health if
  required
• Review and update the risk assessment at least
  once every 3 years or earlier if there is
  significant change to work or process
• Develop and implement safe work procedures for
  works that poses safety and health risks to
  workers
• Keep a written description of the safe work
  procedures and produce this to the inspector for
  inspection when required

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Responsibilities
Employees shall

• Participate in risk assessments
• Adhere to the safe work procedures established
  to reduce any safety and health risks at the
  workplace
• Inform their supervisors of any shortcomings in
  the safe work procedures.

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Hazard Identification
Hazard is defined in WSHA as
Anything with the potential to cause bodily harm
or injury, and includes any physical, chemical,
biological, mechanical, psychosocial, electrical
or ergonomic hazard.
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Hazard Identification
Section 1 in Risk Assessment Form
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Hazard Identification
Steps for Hazard Identification
Step 1 Breakdown of activities (1b) Step 2
Identify the hazards of each step (1c) Step 3
Identify the consequence(s) of each hazard (1d)
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Hazard Identification
Examples of activities

• Metal stamping
• Drum painting
• Drying of painting in oven
• Removal of stuck material from machine
• Material shearing
• Etc.

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Hazard Identification
Broad categories of hazards in metalworking
industry

• Mechanical
• Noise
• Electrical
• Chemical
• Driving
• Ergonomics
• Others

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Hazard Identification
Mechanical Hazards

• Rotating, reciprocating, transverse actions
• Cutting, severing services
• In-running nip points.

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Source Technical Advisory For Metalworking
Industry Understanding the Hazards of
Metalworking Industry
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Hazard Identification
Noise
Noise can be generated by

• Metal shearing
• Material / product handling
• Equipment

Metal shearing
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Hazard Identification
Electrical hazards

• Electrical tools
• Broken plugs
• Electrical wires
• Instruments

Improper Plugs
Source Technical Advisory For Metalworking
Industry Understanding the Hazards of
Metalworking Industry
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Hazard Identification
Chemical hazards

• Solvents in paints
• Acids and alkalis
• Adhesives
• etc

Exposure to Chemicals
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Hazard Identification
Dermatitis due to Exposure to Chemicals
Source Technical Advisory For Metalworking
Industry Understanding the Hazards of
Metalworking Industry
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Hazard Identification
Dermatitis due to Exposure to Chemicals
Source Technical Advisory For Metalworking
Industry Understanding the Hazards of
Metalworking Industry
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Hazard Identification
Driving (forklift)

• Overloading
• Improper use of forklift
• Over speeding
• Inadequate maintenance
• Untrained operator

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Hazard Identification
Source EIGA Safety Newsletter, SAG NL N 81/05/E
Overturning due to high speed
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Hazard Identification
Source EIGA Safety Newsletter, SAG NL N 81/05/E
Improper use of forklift
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Hazard Identification
Incident due to blocked vision
Source EIGA Safety Newsletter, SAG NL N 81/05/E
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Hazard Identification
Ergonomic hazards

• Repetitive activity
• Manual handling of heavy items
• Improper posture
• etc

Source www.speedyhire.co.uk/safety/manual_handlin
g.aspx
Improper Material Handling
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Hazard Identification
Source Applied Ergonomics, D.C. Alexander
Squatting Down to Activate Machine
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Hazard Identification
Source Applied Ergonomics, D.C. Alexander
Standing and reaching to the load, standing on
balls of the feet
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Hazard Identification
Material Loading
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Identification of Risk Controls
Section 2a. in Risk Assessment Form
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Identification of Risk Controls
Hierarchy of Controls
Risk level must be reduced to medium at least
before the start of work. Additional controls
shall be implemented residual risk level is high.
The hierarchy of controls are
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Identification of Risk Controls
Mechanical hazards

• Machine guarding (engineering control)
• Using material handling devices (engineering
  control)
• Two-hand control system (engineering control)
• Sensor control system (engineering control)

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Identification of Risk Controls
Fixed Guard
Material Handling Device
Source Technical Advisory For Metalworking
Industry Understanding the Hazards of
Metalworking Industry
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Identification of Risk Controls
Sensor System
Source Technical Advisory For Metalworking
Industry Understanding the Hazards of
Metalworking Industry
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4. How to operate machines safely
Two-hand Control
Source Machine Guarding, OSHA Office of Training
and Education
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Identification of Risk Controls
Noise hazard

• Equipment design with lower noise level
  (engineering control)
• Use noise wall or other proper containment/Isolati
  on (engineering control)
• Use proper hearing protection equipment (noise
  reduction rating) (PPE)

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Identification of Risk Controls
Hearing Protection Equipment
Total Enclosure of Machine
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Identification of Risk Controls
Electrical hazards

• Proper Lockout and Tagout (LOTO) System
  (administration control)
• Inspection of electrical tools before use by
  qualified persons (administration control)
• Permit to Work (PTW) System (administration
  control)

LOTO System
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Identification of Risk Controls
Chemical hazards

• Use less toxic chemicals (substitution)
• Replace with water-based chemicals (substitution)
• Use Local Exhaust Ventilation (LEV) system
  (engineering control)
• Use Safety Data Sheet (SDS) for instructions
• Use proper PPE
• Regular hygiene monitoring

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Identification of Risk Controls
Replace with Water-based chemicals
Local Exhaust Ventilation (LEV) System
Source Technical Advisory For Metalworking
Industry Understanding the Hazards of
Metalworking Industry
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Identification of Risk Controls
Personal Hygiene Monitor
Selection of Proper PPE
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Identification of Risk Controls
Selection of Proper PPE
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Identification of Risk Controls
Use of Secondary Containment
Use of Spill Control Materials
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Identification of Risk Controls
Driving

• Driver to be properly trained
• Do not overload
• Ensure clearance in the plant
• Control driving speed
• Do not leave the key in the forklift
• Lower the fork when no load
• Ensure no vision blockage

Switch off and Take the Key
Video Camera in Forklift
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Identification of Risk Controls
Source Code of Safe Working Practices Amendment
6, MCA, UK
Ergonomic hazards

• Use leg for lifting, rather than waist
• Correctly position your feet
• Use equipment to aid manual handling

Correct Lifting Position
Source Code of Safe Working Practices Amendment
6, MCA, UK
Use Equipment to Aid
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Risk Evaluation
Section 2b2d. in Risk Assessment Form
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Risk Evaluations
Likelihood Definition by MOM
Severity Definition by MOM
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Risk Evaluations
MOM Risk Assessment Matrix
Risk Level Likelihood Severity
MOM Risk Assessment Matrix
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Risk Evaluation
Requested Actions for Various Risk Level
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Additional Control Measures
Section 3a. in Risk Assessment Form
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Additional Control Measures
Additional control measures shall be identified
when

• Risk level (Section 2d) is identified as high
  risk after implementation of existing control
  measures
• Improvements can be made to further reduce the
  risk

Additional control measures shall be identified
following the hierarchy of control measures.
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Additional Control Measures
Besides the control measures mentioned earlier
for each hazard, Safe Work Procedures
(administrative control) shall be established and
maintained for all works including

• Routine work normal daily operation of machines
• Non-routine work (Ad-hoc work) maintenance

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Additional Control Measures
Safe Work Procedures shall be established when
other control measures cannot reduce the hazards
to a practical level. Examples are as follows

• Hot work
• Painting
• Manual handling
• Driving safety

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Assign Responsible Person and Timeframe
Responsible person and timeframe for each
identified additional control shall be assigned
to ensure effective closeout of action items.
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Maintenance of Risk Assessment
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Records of Risk Assessments
Sample Risk Assessment from MOM
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Provision of Information
Employer, self-employed person and principal
shall inform any person at risk of

• The nature of the risk involved and
• Any measure of safe work procedure implemented.

Employer, self-employed person and principal
shall inform any person at risk of any change in
control measure or safe work procedure.
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Review of Risk Assessments
Risk assessment must be done wherever

• New information on safety and health risks
  surface
• There are changes to the area of work or
  process
• There are accidents or serious incidents
• After a fixed period of time (Max. 3 years)

Revised risk assessment must be communicated to
relevant parties.
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Review of Risk Assessments
The effectiveness of risk control measures can be
evaluated by

• Conducting safety inspection or audit on the
  facility
• Obtaining feedback from employees about the
  measures implemented
• Review of statistical data such as accident /
  incident rate, fatality rate, number of
  hospitalization, plant down time, etc
• Feedback from training assessment / examination

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Exercises
Conduct a risk assessment for your activities in
the company.

• Following the flow provided in the MOM Risk
  Assessment Form
• Use the likelihood and severity table from MOM
• Risk level shall be decided using MOM Risk
  Assessment Matrix.

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Summary
After this training, you should have understood

• The liability you have in violation of the WSH
  (Risk Management) Regulations
• What are the hazards associated with your work?
• What are the control measures for each hazards?
• How is risk assessment conducted based on MOM
  requirements?
• What should you get involved in risk assessment?

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References
You can find more information from the references
below

• National OSH Programme-Based Engagement (ProBE),
  Technical Advisory For Metalworking Industry
  Understanding the Hazards of Metalworking
  Industry.
• EIGA Safety Newsletter, SAG NL N81/05/E.
• Risk Management Risk Assessment Guidelines, MOM
• Guidelines for Noise and Vibration Control, MOM
• Guidelines on Hearing Conservation Program, MOM
• Code of Safe Working Practices Amendment 6, MCA,
  UK
• Concepts and Techniques of Machine Safeguarding,
  U.S. Department of Labor, OSHA 3067, 1992
  (Revised)

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Thank you!