Reports of Hazards in Kaolin Production Packing Line

Reports of Hazards
in Kaolin Production Packing Line of
Indirect Heat X (IDX) Section of
Company Industrial Minerals Sdn Bhd
(Pseudonym)
By
Angela Melodie Liam
Safety and Health Officer Examination
Paper IV Part 1: Workplace Assignment

TABLE OF CONTENTS
No. Chapter Page
1.0 Abstract 1
2.0 Introduction 2
2.1 Company Business Profile 2
2.2 Kaolin Mineral 3
2.3 Company Work Process 4
2.3.1 Business Process 4
2.3.2 Production Process at Tapah Plant 4
2.4 Workplace Assignment: Production Packing Line - Indirect Heat X 6
2.4.1 Production Line - Indirect Heat X (IDX):
Layout Plan, List of Equipment and Processing Sequence
8
2.4.2 IDX Rotary Dryer 9
2.4.3 IDX Packing Operators 9
2.4.4 IDX Workplace Environment 11
3.0 Objectives 13
3.1 General Objectives 13
3.2 Specific Objectives 14
4.0 Method 15
4.1 Methods 15
4.2 Risk Assessment 21
5.0 Result and Discussion 26
5.1
Health Hazards and Safety Hazards identified at Indirect Heat X
(IDX) according to the Risk Criticality
26
5.2 Risk Rating for Health Hazard and Safety Hazard 34
5.3 Rational for Selections of Critical Hazards 38
5.3.1 Critical Safety Hazard Selection 38
5.3.2 Critical Health Hazard Selection 44
5.4
Impact of Critical Safety and Health Risks identified to the
Organization
50
6.0 Recommendation 55
6.1 Safety Hazard Proposed Control Measures 57
6.2 Health Hazard Proposed Control Measures 60
6.3
Explanation on the proposed review program on the effectiveness of
the proposed control measures in subsection 6.1 and 6.2.
62

6.4
Discuss the benefits of the recommendations in subsection 6.1 and
6.2 to the organization.
63
7.0 References 64
8.0 Appendices 68
Glossary

1
1. ABSTRACT
Company Industrial Minerals Sdn Bhd (pseudonym) is a mining and manufacturing industry
located at Tapah, Perak specialising in a specific industrial minerals known as kaolin clay or
hydrated aluminium silicate (Chemical Name: Al2Si2O5(OH)4). The main aim of this
assignment is to identify, evaluate and provide recommendations in controlling occupational
hazards and health hazards to the management of Company Industrial Minerals Sdn Bhd
(pseudonym) in order to create a win-win situation between the employer and employee of the
company in the long-term and to comply with the safety legislation of Malaysia. In order to
comply with these objectives, the Hazard Identification, Risk Assessment and Risk Control
(HIRARC) methods was used.
The workplace in focus is the Production Line - Indirect Heat X (IDX) which uses a Burner
and Rotary Dryer that fires up to two hundred thirty degree Celsius (230˚C). IDX produces an
approximate median tonnage of four hundred and eighty metric tonnes (480 MT) per month.
For the month of January to February 2018, IDX produces around eighteen metric tonnes (18
MT) daily, packed into 25Kg Paper Bags (9MT per shift).
The objective of this report is to identify six Safety and Health Hazards with at least two
Health Hazards at the workplace. Four (4) Safety Hazards and four (4) Health Hazards have
been identified at IDX. The methodologies that have been used to gather all information
needed for both day and night shift packing operator working at IDX include inspection and
observation of the workplace through Workplace Audit, Workplace assessment through
Interview with Worker which include worker’s complaint and comments; and hazard
analysis – Job Safety Analysis.
The most critical Safety hazard is Mechanical Hazard caused by overturn of Forklift Truck
while maneuvering and transportation finished goods into warehouse. Statistics shows that
there is at least one fatality recorded by Department of Safety and Health (DOSH) around
Malaysia. The most critical Health Hazard is Chemical Hazard caused by kaolin dust
particulates exceeding the permissible limit guidelines by regulatory bodies. According to
studies complied by the World Health Organization (WHO), kaolin dust particulates has
chronic effects on our respiratory system and can cause Occupational Asthma categorized
under Radiological Pneumoconiosis called kaolinosis. It also can cause fibrosis.
The appropriate control measures have been suggested to overcome the problems caused. The
most appropriate preventive control measures for Safety Hazard which is budget friendly for
this organization is substitution of traditional concrete warehouse flooring to Industrial Epoxy
Flooring. The corrective Control measure is to patch the existing potholes and cracks and
smoothen and lowered uneven surfaces.
The most appropriate preventive control measures for Health Hazard which is budget friendly
for this organization is Engineering Control using Isolation of machinery from worker by
providing air-controlled room for packing operator with Local Exhaust Ventilation at Packing
Valve Machine. The corrective control measure is to provide a N95 mask with valve or half-
face silicon respirator mask fitted with filter.
These control measures will improve the safe work practice as well as give benefits for both
parties, employer and employee and reduce or minimize the number of injuries and accidents.

2
2. INTRODUCTION
2.1 Company Business Profile
Company Industrial Minerals Sdn Bhd (pseudonym) is a leading producer of high quality kaolin
minerals found in the surrounding areas of Tapah, Perak. The Factory is located at Batu 38 ¾, Jalan
Tapah-Bidor, 3500 Tapah Perak. Established since 1970, the company has produced gradually about
80,000 tonnes of products annually. The company is currently headed by the Managing Director, Mr.
Lee Chor Teck and has a total of 60 employees in both its Headquarter located at Puchong, Selangor
and Factory located at Tapah, Perak. The Tapah Factory is led by the Plant Manager, Mr. Sundaresan
A/L Palaniandy. He manages a total of five (5) departments – Admin and Purchasing Department,
Production Department, Quality Control and Admin Department, Engineering Department and Mining
Department which is operated by a total of 47 employees. Refer to Appendix, Chart 1: Company
Industrial Minerals Sdn Bhd (pseudonym) Organisation Chart.
Kaolin is a very versatile mineral. Currently, more than fifty percent (50%) of kaolin is exported to
international markets such as Europe, United States of America, the Middle East, South Africa,
Pakistan, Bangladesh, India, Indonesia, Japan and many other Asian markets. Among the industries
which uses kaolin mineral in the formulation of their products are Paint, Rubber, Plastic, Ceramic,
Cosmetic, Beauty, Health and Wellness, Medicine, Agriculture Fertilizer, Pesticide, Paper and many
more.

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2.2 Kaolin Mineral
Kaolin mineral is a type of chemically hydrated aluminium silicate (Chemical Name:
Al2Si2O5(OH)4) and structurally unmodified. Kaolin is platy in structure, hydrophilic and readily
water dispersible. Before kaolin crude can be put to good use, it has to go through several production
processes.
First, kaolin crude clay is excavated from the mining pit. Water washed kaolin is made by slurrying
the raw clay and then centrifuging or hydrocycloning it to remove impurities. Chemical bleaching is
done to improve the brightness of the kaolin before it is then dried either using natural drying methods
or using an indirect heat burner. The dry clay is then segregated into specific grades and packed into
into 25kg, 50kg, 500kg and 1MT bags to cater to different customers’ need.
Figure 1:0:1 - Kaolin particles under the Scanning
Electron Microscope (SEM) magnified at 5000 times
Figure 1:2 – Refined kaolin powder after final process

4
2.3 Company Work Process
2.3.1 Business Process
The company’s business process begins when the Sales and Marketing Team forecast or
received confirmed orders from the customers. The order will be processed and
communicated to Tapah Factory and the Procurement Team. Tapah Factory shall plan the
mining, process and production activities as well as maintain product quality whereas the
Procurement Team shall ensure that the packing materials for the production of the products
are sufficient. When the products are ready as per ordered, the Sales and Marketing Team
shall arrange delivery to the customer. Refer to Chart 2: Company Industrial Minerals Sdn
Bhd (pseudonym) Business Flow Chart.
2.3.2 Production Process at Tapah Plant
Kaolin crude or commonly known as crude clay has to go through several production
processes before refined kaolin mineral is produced. The summary of the steps are as per
below:-
i) Kaolin crude is extracted by excavators from the mining pit.
ii) Trucks then transport the kaolin crude to the processing plant storage yards’.
iii) At the plant, the mixture of clay and water, commonly referred to as slurry, is passed
through a series of filtering and dewatering tanks.
iv) During the process, fine sand and mica are extracted from the clay particles through
suspension in water.
v) The clay is meanwhile subjected to a number of complex chemical treatments to
produce the different grades for the final product.

5
vi) Treated slurry is next passed through the filter press where most of the water is removed
from the clay, resulting in slabs of pressed kaolin cake.
vii) Finally, the slabs of pressed kaolin cake are cut into smaller pieces and place in drying
sheds for natural drying or undergo a drying process through the indirect heat burner for
low moisture products.
Chart 3: Kaolin Factory Mining & Production Process Flow

6
2.4 Workplace Assignment: Production Packing Line - Indirect Heat X (IDX)
IDX produces a median tonnage of four hundred metric tonnes (400 MT) per month. For the month of
January to February 2018, IDX produces around nine metric tonnes (9 MT) per shift daily. It is either
packed into 25Kg Paper Bags or 500kg Flexible Jumbo Bag. The data for these can be referred at
Appendix: IDX Production Information Data.
Figure 1:3 - Production Packing Line - Indirect Heat X (IDX), Front Entrance

7
Production Line Indirect Heat X (IDX)

8
2.4.1 Production Line - Indirect Heat X (IDX):
Layout Plan, List of Equipment and Processing Sequence
The focused section for this workplace assignment is the “Production Line - Indirect Heat X (IDX)”.
The Location of IDX and Filter Press Machine can be referred at Chart 4: Location of Filter Press
Machine and IDX. A detailed Layout of IDX machines and equipment setup can be referred at Chart 5:
Floor Plan Layout IDX & IDY.
The drying process begins when semi-dry pressed cakes are dropped from the Filter Press Machine
onto the track-belt and carried firstly, to Indirect Heat Y (IDY) for the first stage process where the
filter pressed cake is transformed to semi-dry lump form clay with moisture content percentage of
about twenty (20%). The lump form clay is then transported via Conveyor Belt No. 6 into Cake
Mixing Hopper A at IDX section and the process continues as per sequenced. The Rotary Dryer at
IDX is fired up to two hundred fifty degree Celsius (250˚C). After drying process is complete the dry
powders goes through a more extensive process which gives time for it to cool down before the
Packing Operator pack it into bags and conduct weight check. After that, the bags are stacked onto
pallets, counted, labelled with batch numbers, compacted and cleaned before being sent to the
warehouse for storage. The processing sequences are as per reflected in Chart 6: Processing Sequence
of IDX Section.
Chart 6: Processing Sequence of IDX Section

9
2.4.2 IDX Rotary Dryer
Indirect-heat rotary dryer is ideal for processing dusty, fine materials, or materials that cannot be
exposed to oxygen or combustion gases during processing. The dryer is comprised of a rotating drum
in which the processing occurs. It is constructed using a high temperature alloy, in order to maintain
the integrity of the drum, despite the constant exposure to high temperatures that the shell must endure.
The dryers rely on the heat emanating from the drum’s shell to dry the material via conduction and
radiation. It allows you to tightly control the processing environment which is an ideal characteristic
when working with materials that cannot come into contact with process gases. Process gas is gas
produced by an industrial process. No process gas can move through the drum of the dryer.
2.4.3 IDX Packing Operators
The Production Department is headed by Mr. Gnanapragasam A/L Gopal. There are two
operators working at IDX section. Each operator works a twelve hours shift with 1 hour break
time. The details of the operators are as per below:-
IDX Operator
Day Shift
IDX Operator
Night Shift
Name Azmeer Hossain Rajak Mohan Lal
Age 32 years old 25 years old
Gender Male Male
Origin Bangladesh Nepal
Height 167cm 160cm
Weight 55kg 51kg
Medical History NIL NIL
Working Hours 8am – 8pm 8pm – 8am
Year Start Work 2017 2016
Salary Incentive base. According to tonnage produced.
The Job Description and the Work Instruction for the Packing Operators are as per described in
Appendix 1.

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IDX packing line operations can be summarized as per below:-
1. Operator inserts a piece of 25Kg Paper Bag into the Valve Packing Machine Nozzle and
positions it horizontally in the middle of the packing platform.
2. Operator push the “On” button on Control Panel located beside the Valve Packing
Machine manually for each bag.
3. The air force in the Silo Tank gush out together with the Kaolin mineral stored in the Silo
Tank is the Valve Packing Machine Nozzle into the 25kg Paper Bags.
4. Valve Packing Machine will auto-cut off abruptly upon reaching the 25Kg weight.
Chart 7: Packing Operators Work Instructions describe in more details of the packing operators job
requirements. Although the Work Instruction shows that they are only required to pack products into
bags, conduct weight check, stacked the bags onto pallets, count the quantity of bags, label batch
number on the palletized product, compact and clean the palletized products and to carry it to the
designated area, their work is very repetitive and no schedule was done up by Human Resource
Department for job rotation with other sections or departments.
2.4.4 IDX Workplace Environment
The Indirect Heat X (IDX) Production and Packing Line is sharing a warehouse with Indirect
Heat Y Production Line (IDY). IDY does not have a Packing Line installed. The warehouse is
naturally ventilated and no fans or mechanical exhaust ventilation are installed. There is no
segregation barrier between IDX and IDY. The warehouse has minimal containment structure.
It has only 2 walls situated at the right and left sides of the warehouse, whereas the front and
back entrance is wide open. No shutters and locks are installed at both entrances.

12
Indirect Heat X (IDX) work environment are as per below:-
a. Air Quality - IDX is extremely dusty environment with airborne kaolin dust especially during
production process and movement of mobile equipment.
b. Ventilation - The IDX section is using natural ventilation and no fans was installed to create air
flow. It is hot during the afternoon.
c. Security - There are also no doors or locking system on both front entrance and back entrance.
d. Lighting - Day Shift uses natural sunlight whereas Night Shift uses florescence lighting at four (4)
corners of the IDX sections.
e. Vibration - Minor vibration made by machinery and equipment which causes the source of noise
f. Noise - Source of Noise comes from Rollers, Bearings, Forklift, Hammer Mill, Suction Fan, Dryer,
Belt, Burner
g. Housekeeping - Kaolin powders accumulated into mole hills at a few areas at IDX blocking the
back entrance and access to IDX equipment.
h. Traffic - No lines drawn on warehouse floor to distinguish the walk-way, mobile equipment
driveway, packing area and machine area.
i. Communication - Communication between Foreign Workers and Head of Departments (Local
Workers) are poor due to poor verbal and written English and Bahasa Melayu language
proficiency of the Foreign Workers.

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3. OBJECTIVES
Hazard Identification, Risk Assessment and Risk Control (HIRARC) have become
fundamental to the practice of planning, management and the operation of a business as a
basic of risk management. The assessment is done in accordance with the Department of
Occupational Safety and Health (DOSH) Malaysia Legislation Guideline for HIRARC in
order to provide a systematic and objective approach to assessing hazards and their associated
risks that will provide an objective measure of an identified hazard as well as provide a
method to control the risk. The HIRARC Guidelines is intended for the assessment of
physical hazards.
3.1 General Objectives
i) To comply with the legal requirements set out in the Occupational Safety and Health
Act 1994, Act 514 (OSHA 1994), Part IV, General Duties of employers and self-
employed person - Regulation 15 (1) and Regulation 15 (2).
ii) Meeting the legal requirements set out in the Occupational Safety and Health (Safety
and Health Officer) Regulations, Part V, Duties of Safety and Health Officers -
Regulation 18 (a), Regulation 18 (b) and Regulation 18 (f).

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3.2 Specific Objectives
1. To identify the safety and health hazards that may cause harm to employees at Production
Line of Indirect Heat X (IDX) work area.
2. To evaluate the chances of safety and health risk for the identified hazards as per Risk
Assessment technique by quantitative and qualitative risk assessment.
3. To evaluate the adequacy of existing control measures
4. To propose further rational control measures, preventive measures and corrective
measures appropriate for the company to prevent or reduce risk and exposure as
necessary as when required
5. To enable employers to plan, introduce and monitor preventive measures to ensure that
the risks are adequately controlled at all times.

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4. Method
4.1 Methods of Identifying Hazards at Production Line – Indirect Heat X (IDX)
The methodology adopted for this assessment is from the “Guidelines for Hazard
Identification, Risk Assessment and Risk Control (HIRARC), Year 2008” by the Department
of Occupational Safety and Health Malaysia. Hazard Identification is important to highlight
the critical operations of tasks that could pose significant risks to the safety and health of
employees pertaining to certain equipment due to energy sources, working conditions or
activities performed.
For the purpose of this assignment, out of the three main groups of hazards listed, only two
groups of hazards are in focused, which are the Health Hazards and Safety Hazards.
Definition of Health Hazards
An occupational health hazard is any agent that can cause illness to an individual. A health
hazard may produce acute effects or chronic problems. All parts of the body may be affected.
Someone with an occupational illness may not recognize the symptoms immediately. Health
Hazards that will be assessed at this workplace includes:
i) Chemicals
ii) Biological hazards
iii) Physical agents
iv) Work design (ergonomics) hazards.

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Definition of Safety Hazards
A safety hazard is a force strong enough to cause injury, or damage to property. An injury
caused by safety hazard is usually obvious. Safety hazards cause harms when workplace
controls are not adequate. Below are the lists of safety hazards that will be identified:-
i. Slipping/ tripping hazards
ii. Fire hazards
iii. Moving parts of machinery, tools and equipment
iv. Work at height
v. Ejection of material
vi. Pressure systems
vii. Vehicles
viii. Lifting or manual handling operations
ix. Working alone
Hazard Identification Technique
Various methods can be used to identify the hazards involved during working hours at the
Production Line – Indirect Heat X (IDX). The three (3) methods chosen for identifying these
hazards are:-
i) Workplace Assessment - Interview with Worker
ii) Workplace Inspection - Workplace Audit Inspection
iii) Hazard Analysis - Job Safety Analysis
Sources of Hazards can be traced to Man, Machinery, Materials, Methods or Media. The
hazards materialized when:-

17
 Man practice unsafe acts while on duty at the workplace.
 Improper or unauthorized installation of machinery, machinery layout and design of
equipment are executed
 Material substance such as chemicals and gases used in the workplace which are not used
responsibly are per guidelines
 Methods used to execute tasks at work are inappropriate and nor as per safety guidelines
 Media in workplace such as air quality, ventilation, lighting, noise and vibration is not
within the Permissible Exposure Limit of the Occupational Safety and Health Act and
Regulations and Factories and Machinery Act with Regulations.
Workplace Inspection - Workplace Audit and Interview with Worker
Workplace inspections help prevent incidents, injuries and illnesses. Through a critical
examination of the workplace, inspections help to identify and record hazards for corrective
action. Health and safety committees can help plan, conduct, report and monitor inspections.
Regular workplace inspections are an important part of the overall occupational health and
safety program and management system, if present.
Inspections are important as they allow you to:
 Man practice unsafe acts while on duty at the workplace.
 listen to the concerns of workers and supervisors
 gain further understanding of jobs and tasks
 identify existing and potential hazards
 determine underlying causes of hazards
 recommend corrective action

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 monitor steps taken to eliminate hazards or control the risk (e.g., engineering controls,
administrative controls, policies, procedures, personal protective equipment)
Every inspection must examine who, what, where, when and how. Pay particular attention to
items that are or are most likely to develop into unsafe or unhealthy conditions because of
stress, wear, impact, vibration, heat, corrosion, chemical reaction or misuse. Include areas
where no work is done regularly, such as parking lots, rest areas, office storage areas and
locker rooms.
Look at all workplace elements – the people, the environment, the equipment and the process.
The environment includes such hazards as noise, vibration, lighting, temperature, and
ventilation. Equipment includes materials, tools and apparatus for producing a product or a
service. The process involves how the worker interacts with the other elements in a series of
tasks or operations.
Hazard Analysis - Job Safety Analysis
Every job in your plant should be considered hazardous unless being considered otherwise.
You therefore need to analyse such job thoroughly. Accidents can and will be reduced by
training operators / workers to do their work safely. One basic element to accomplish a good
work safety program is Job Safety Analysis (JSA). It provides a method for systematically
identifying hazards in jobs and developing step-by-step procedures to eliminate them.

19
A job safety analysis (JSA) is a procedure which helps integrate accepted safety and health
principles and practices into a particular task or job operation. In a JSA, each basic step of the
job is to identify potential hazards and to recommend the safest way to do the job.
One of the methods used in this example is to observe a worker actually performing the job.
The major advantages of this method include that it does not rely on individual memory and
that observing or performing the process prompts the recognition of hazards. For infrequently
performed or new jobs, observation may not be practical.
One approach is to have a group of experienced workers and supervisors complete the
analysis through discussion. An advantage of this method is that more people are involved in
a wider base of experience and promoting a more ready acceptance of the resulting work
procedure. Members of the health and safety committee must also participate in this process.
Initial benefits from developing a JSA will become clear in the preparation stage. The
analysis process may identify previously undetected hazards and increase the job knowledge
of those participating. Safety and health awareness is raised, communication between workers
and supervisors is improved, and acceptance of safe work procedures is promoted.
A JSA, or better still, a written work procedure based on it, can form the basis for regular
contact between supervisors and workers. It can serve as a teaching aid for initial job training
and as a briefing guide for infrequent jobs. It may be used as a standard for health and safety
inspections or observations. In particular, a JSA will assist in completing comprehensive
accident investigations.

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Four basic stages in conducting a JSA are:
i) selecting the job to be analysed
ii) breaking the job down into a sequence of steps
iii) identifying potential hazards
iv) determining preventive measures to overcome these hazards
JSA will require revision whenever equipment, raw materials, processes, or the environment
change. For these reasons, it is usually necessary to identify which jobs are to be analyzed.
Even if analysis of all jobs is planned, this step ensures that the most critical jobs are
examined first.
Factors to be considered in setting a priority for analysis of jobs include:
i. Accident frequency and severity: jobs where accidents occur frequently or where they
occur infrequently but result in serious injuries.
ii. Potential for severe injuries or illnesses: the consequences of an accident, hazardous
condition, or exposure to harmful products are potentially severe.
iii. Newly established jobs: due to lack of experience in these jobs, hazards may not be
evident or anticipated.
iv. Modified jobs: new hazards may be associated with changes in job procedures.
v. Infrequently performed jobs: workers may be at greater risk when undertaking non-routine
jobs, and a JSA provides a means of reviewing hazards.

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4.2 Methods of Risk Assessment
Risk is the determination of Likelihood and Severity of the credible accident/ event sequences
in order to determine magnitude and to priorities identified hazards. It can be done by
Qualitative, Quantitative or Semi Quantitative Method.
A Qualitative Analysis uses words to describe the magnitude of potential severity and the
Likelihood that those Severity will occur. These scales can be adapted or adjusted to suit the
circumstances and different descriptions may be used for different risks. This method uses
expert knowledge and experience to determine likelihood and severity category.
LIKELIHOOD
Very
Likely
Likely Unlikely
Highly
Unlikely
SEVERITY
First Aid and Near-Misses High High High Medium
Less than 4 days MC High High Medium Medium
More than 4 days MC High Medium Medium Low
Fatality & Permanent Disability Medium Medium Low Low
Qualitative Risk Table
Quantitative analysis uses numerical values for both severity and likelihood using data from a
variety of sources such as past accident experience and from scientific research. Severity may
be determined by modelling the outcomes of an event or set of events, or by extrapolation
from experimental studies or past data. Severity may be expressed in terms of monetary,
technical or human impact criteria, or any other criteria. The way in which severity and
likelihood are expressed and the ways in which they are combined to provide a level of risk
will vary according to the type of risk and the purpose for which the risk assessment output is
to be used.

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LIKELIHOOD
Yearly Monthly Weekly Daily
1 2 3 4
SEVERITY
First Aid and Near-Misses 1 1 2 3 4
Less than 4 days MC 2 2 4 6 8
More than 4 days MC 3 3 6 9 12
Fatality & Permanent Disability 4 4 8 12 16
Semi-Quantitative Risk Assessment Table
Semi-quantitative analysis uses qualitative scales such as those described above are given
values. The objective is to produce a more expanded ranking scale than is usually achieved in
qualitative analysis, not to suggest realistic values for risk such as is attempted in qualitative
analysis. For the purpose of this workplace assignment, Qualitative and Semi-Quantitative
methods are used.
Likelihood of an occurrence
This value is based on the Likelihood of an Event occurring. You may ask the question “How
many times has this event happened in the past?” Assessing Likelihood is based worker
experience, analysis or measurement. Base on Likelihood levels range from “most likely” to
“inconceivable”.
LIKELIHOOD (L) EXAMPLE RATING
Most Likely The most likely result of the hazard/ event being realized 5
Possible Has a good chance of occurring and is not unusual 4
Conceivable Might occur at some time in future 3
Remote Has not been known to occur after many years 2
Inconceivable Is practically impossible and has never occurred 1
Table A: Likelihood

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Severity of Hazard
Severity can be divided into five categories. Severity are based upon an increasing level of
severity to an individual’s health, the environment or to property.
SEVERITY (S) EXAMPLE RATING
Catastrophic
Numerous fatalities, irrecoverable property damage and
productivity
5
Fatal
Approximately one single fatality major property damage
if hazard is realized
4
Serious Non-fatal injury, permanent disability 3
Minor Disabling but not permanent injury 2
Negligible Minor abrasions, bruises, cuts, first aid type injury 1
Table B: Severity

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Risk Assessment
Risk can be presented in variety of ways to communicate the results of analysis to make
decisions on risk control. This risk analysis uses Likelihood and Severity in Qualitative
Method, presenting result in a Risk Matrix to communicate the distribution of the risk
throughout the area in the workplace.
The Formula for Risk is:
L x S = Relative Risk,
L = Likelihood
S = Severity
SEVERITY (S)
1 2 3 4 5
LIKELIHOOD(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
High Medium Low
To use this matrix, first find the severity column that best describes the outcome of risk. Then
follow the Likelihood row to find the description that best suits the Likelihood that the
Severity that will occur. The risk level is given in the box where the row and column meet.
The Relative Risk value can be used to prioritise the necessary actions to effectively manage
work place hazards. Table D determines priority based on the following ranges:

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RISK DESCRIPTION ACTION
15 - 25 High
A High Risk requires immediate action to control
the hazard as detailed in the hierarchy of control.
Actions taken must be documented on the risk
assessment form including date for completion.
5 - 12 Medium
A Medium Risk requires a planned approach to
control the hazard and applies temporary measures
if required. Actions taken must be documented on
the risk assessment form including date of
completion.
1 - 4 Low
A risk identified as Low Risk may be considered as
acceptable and further reduction may not be
necessary. However, if the risk can be resolved
quickly and efficiently, control measures should be
implemented and recorded.
Table D: Priority base on Risk Value
Hazard assessed as High Risk must have immediate actions to resolve risk to life safety and or
to the environment. Individuals responsible for required action, including follow up must be
clearly identified. A further detail risk assessment method may require such as Quantitative
Risk Assessment as means of suitable control measures.

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5. RESULT AND DISCUSSION
5.1 Health Hazards and Safety Hazards identified at Indirect Heat X (IDX) according to
the Risk Criticality
Critical Risk - High Severity: It has record to cause grave harm and danger. Means it has high
severity
1. Hazard Identification – Safety Hazard
Ref.
No.
Work
Activity
Work Activity
Description
Hazard
Consequence
Impact
1 Forklift
Operations,
Manoeuvring
&
Transportation
of finished
goods into
warehouse
Exposure Duration:
11 hours
Days:
Monday - Saturday
Salary:
Incentive base
according to
tonnage of product
produced
Average Daily
Production:
9MT/ shift
(9 pallets)
Distance to
Warehouse
Storage: 500m
Type: Safety Hazard
Classification:
Mechanical - Vehicles
– Forklift Truck Overturn
Description:
Vehicle (Forklift Truck)
overturns due to uneven
surfaces and unsecured
and unstable Load while
manoeuvring
Fatality or
Permanent Injury.
 Operator Slip
and Fall out
from Forklift
Truck onto the
ground.
 Worker body
parts (Feet, arm,
head) may be
crushed and
broken by
Forklifts when it
overturns to the
side.
 Worker may also
suffer from
bruises or
scratches on
body parts.

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Ref.
No.
Work Activity
Work Activity
Description
Hazard
Consequence
Impact
2 Filling in kaolin
powder into
25kg paper bag
Exposure Duration:
11 hours
Days:
Monday - Saturday
Salary:
Incentive base
according to
tonnage of product
produced
Average Daily
Production:
9MT/ shift
(360 bags)
Type: Safety Hazard
Classification: Work
Environment - Fall,
Trip & Slip
– on Powder Leakage
and Excessive
Accumulation of
Wastage on worker
working path
Description:
Walking Path is not
free from obstructions
of accumulated
powders, forming
small hills. Proper
Housekeeping cannot
be done due to too
many powder leakages
from machines. Floors
are also not free of
boxes, swarfs, off-cuts
& other trip hazards,
hidden by powder
wastage.
No designated walking
and driving path and
no designated area to
place pallets and do
compacting and
blowing of end
product available as
lines cannot be drawn
on the floor.
Slip, Trip and Fall
which can lead to
minor bump or
abrasion on body
parts

28
Ref.
No.
Work
Activity
Work Activity
Description
Hazard
Consequence
Impact
3 Operator
walks about
to manage
the
operation of
IDX
Machineries
and
preparation
of Product
Packing
(25KG
Paper Bags)
at Packing
Area.
Exposure Duration:
11 hours
Days:
Monday - Saturday
Salary:
Incentive base
according to tonnage
of product produced
Average Daily
Production:
9MT/ shift (360 bags)
Type: Safety Hazard
Classification:
Work Environment -
Fall, Trip & Slip
(Physical Hazard)–
Kaolin Powder wastage
accumulating on floor
mix with rain water
Description:
Slip, Trip and Fall due
to wet and muddy floor
surfaces which will be
slippery especially
during rainy season or
when there is liquid
spillage on floor.
Uneven Patches will
make the Trip Hazard
more prone.
Accumulated powder
on floor will make mud
formation easily
formed. Mud will also
clump to safety boot's
sole which would lead
to slip, trip and fall.
Slip, Trip and Fall.
Minor bruises or
scratches on body
parts.

29
Ref.
No.
Work
Activity
Work Activity
Description
Hazard
Consequence
Impact
4 Arranging
of bags on
pallets
Exposure Duration:
11 hours
Days:
Monday - Saturday
Salary:
Incentive base
of product produced
Average Daily
Production:
9MT/ shift
(360 bags or 9 pallets)
Arrangements of bags
on pallets start from
the base of the pallet to
the height of
approximately 6 Feet.
Summary of
arrangement:
1 pallet = 40 bags
1 pallet = 10 layers
1 layer = 4 bags
Type: Safety Hazard
Classification:
Manual Handling –
Long hours of Lifting,
Carrying, Repetitive
Movements daily
- Paper and Wood
Material
Description:
Repetitive contact with
rough wood surfaces
on pallets and paper
fibre from paper bags
when doing bag
arrangements on
pallets, blowing of
powders from bags and
wrapping of load.
Cuts on fingers
Splinters penetration
on fingers and hands
Calluses formation

30
1. Hazard Identification- Health Hazard
Ref.
No.
Work
Activity
Work Activity
Description
Hazard
Consequence
Impact
1 Filling in
kaolin powder
into 25kg
paper bag
Exposure Duration:
11 hours
Days:
Monday - Saturday
Salary:
Incentive base
of product produced
Average Daily
Production:
9MT/ shift
(360 bags)
 Operator inserts a
piece of 25Kg
Paper Bag into
the Valve
Packing Machine
Nozzle and
positions it
horizontally in
the middle of the
packing platform.
 Operator push the
“On” button on
Control Panel
located beside the
Valve Packing
Machine
manually for each
bag.
 The air force in
the Silo Tank
gush out together
with the Kaolin
mineral stored in
the Silo Tank is
the Valve
Packing Machine
Nozzle into the
Type: Health Hazard
Classification:
Chemical – Toxic
Description:
 Paper Bag is
swollen due to the
air filling the bag.
 The air will push
the access powder
out from the bag
when it reaches
25kg weight,
causing powder
spillage to occur.
 The dust
particulate from
the spillage will
be released to
environment.
 Operator inhale
kaolin dust
particulate.
 Other dust
particulate
sources released
to same work
environment are
leakages from
Vibrating Screen,
KM Separator
and Reject
powder valve.
 Report from
competent person
shows that
exposure of dust
has exceeded
PEL.
Occupational Asthma
caused by particulate
irritants
Radiological
Pneumoconiosis
(kaolinosis, fibrosis)
Confluent lesions
Massive fibrosis
which can lead to
disablement

31
25kg Paper Bags.
Valve Packing
Machine will
auto-cut off
abruptly upon
reaching the
25Kg weight.
1. Hazard Identification – Health Hazard
Ref.
No.
Work
Activity
Work Activity
Description
Hazard
Consequence
Impact
2 Overall
packing and
handling
operation at
IDX
Exposure Duration:
11 hours
Days:
Monday - Saturday
Salary:
Incentive base
of product produced
Average Daily
Production:
9MT/ shift
(360 bags)
Workplace size:
110 feet x 93 feet
There are a total of
22 equipment at
operating at IDX.
Type:
Health Hazard
Classification:
Energy – Noise
Description:
Source of Noise
comes from
machineries in that
work area,
eg.
1. Valve packing
machines
2. Hammer Mill
Suction Fan
3. Rotary Dryer4.
Conveyor Belt
Overall, there are 22
equipment working
concurrently in IDX.
Worker is unable to
hear someone talking
in a normal voice or
sound of anyone
approaching at 2
metres away when
machineries are in
operation.
Hearing Impairment
caused by noise.
Often the damage
gets gradually worse
with each repeat
exposure.

32
Ref.
No.
Work
Activity
Work Activity
Description
Hazard
Consequence
Impact
3 Weight
check and
arrangement
of bags on
wooden
pallets
Exposure Duration:
11 hours
Days:
Monday - Saturday
Salary:
Incentive base
according to
tonnage of product
produced
Average Daily
Production:
9MT/ shift
(360 bags)
Kaolin mineral
(packed in 25KG
Paper Bags) is
submitted for a
quick weight check
by operator before
being arrange on
pallet.
Arrangements of
bags on pallets start
from the base of
the pallet to the
height of
approximately 6
Feet.
Summary of
arrangement:
1 pallet = 40 bags
1 pallet = 10 layers
1 layer = 4 bags
Type: Health Hazard
Classification: Manual
Handling - Ergonomic,
Lifting, carrying and
Repetitive Movements
Description:
1. Worker bend to pull the
bag mouth out from the
valve.
2. He then lift and carry
the 25kgs paper bag of
processed kaolin powder
with 2 hands to his left
onto the weighing machine
for weight check.
3. Worker then lift, carry
and swing or heave the
bag onto the pallet by
twisting his mid-body
anticlockwise.
4. For the arrangements of
bags at base of pallet,
worker has to bend to do
the arrangements.
5. For arrangements of
bags above worker's
shoulder, worker has to
tip-toed or applies
momentum to his body in
order to see the top, push
and pull in order to
arrange the bags on the
pallet.
6. In 1 day, worker packed
an average of 9MT/ Shift
which is equivalent to 360
bags daily.
Musculoskeletal
Disorders due to
repetitive lifting,
swinging, pushing,
twisting, and
bending of body.
Interview with
worker shows that
they have:-
- Cramp and strain
on the hand, arm.,
neck and abdomen
due to repetitive
movement.
- Strain and ache at
back, shoulder,
stomach, arms,
chest, shoulder, knee
and neck muscles
due to repetitive
movement.
Worker may faint or
weakened due to
work fatigue.
Worker sometimes
have headache and
asked for
Paracetamol.
Common MSDs
include:
Carpal Tunnel
Syndrome
Tendonitis
Muscle / Tendon
strain
Ligament Sprain
Tension Neck etc

33
Ref.
No.
Work
Activity
Work Activity
Description
Hazard
Consequence
Impact
4 Operator
checks
temperature at
Rotary Dryer
daily to ensure
temperature of
dryer is
consistently
230˚C.
Exposure Duration:
Less than 5 minutes
(Rotary Dryer area),
11 hours (Valve
Packing area)
Days:
Monday - Saturday
Salary:
Incentive base
of product produced
Average Daily
Production:
9MT/ shift (360 bags)
Type: Health Hazard
Classification:
Work Environment -
Extreme Temperature
(Heat) – Heat stress
Description:
Contact with extreme
heat from Rotary
Dryer. Temperature
of dryer is set at
230°C.
Overall workplace
environment is
Naturally Ventilated.
No fan provided.
No control in Work
Environment.
Subjected to changes
in weather.
Illness:
Heat Stroke
Heat Exhaustion
Heat Cramp
Heat Rashes
Create symptoms
which leads to
injuries:
sweaty palms
dizziness
Injuries:
Burns

34
5.2 Risk Rating for Health Hazard and Safety Hazard
Qualitative Methods for Risk Analysis are used. The Risk Analysis uses Likelihood (L) and
Severity (S) values to present the Relative Risk (RR) results for IDX workplace.
The Hazards below is prioritized according to the Relative Risk, from the highest to the
lowest Relative Risk Value.
1. Hazard Identification 2. Risk Analysis
Ref.
No.
Hazard
Consequence
Impact
Existing Risk Control
(if any)
Risk Rating
L S R
1 Type: Safety
Hazard
Classification:
Mechanical -
Vehicles
– Forklift Truck
Overturn
Description:
Vehicle (Forklift
Truck) overturns
due to uneven
surfaces and
unsecured and
unstable Load
Fatality or
Permanent Injury.
- Operator Slip and
Fall out from
Forklift Truck onto
the ground.
- Worker body parts
(Feet, arm, head)
may be crushed and
broken by Forklifts
when it overturns to
the side.
- Worker may also
suffer from bruises
or scratches on
body parts.
PPE used:
- Safety Helmet (not strapped)
- Safety Boots is in good
condition.
Administrative Controls:
- Night Shift Worker attended
training for "CAT Lift Truck
Operator Safety Training" on
03/01/18 provided by CAT
Lift Trucks - Tractors Material
Handling
- Day Shift Worker was absent
from formal training.
- WhatsApp Chatgroup to
monitor Forklift condition and
to report any damages,
breakdowns and misused. PIC
has been appointed. Manager -
Jean Ng, Co-ordinator - Gnana.
- Penalty is implemented of
Operators who fail to follow
rules
- Supplier is proactive in
supporting repair &
maintenance
3 4 12

35
2 Type: Safety
Hazard
Classification:
Work Environment
- Fall, Trip & Slip
– Powder Leakage
and Excessive
Accumulation of
Wastage on ground
Description:
- Walking Path is
not free from
obstructions of
accumulated
powders, forming
small hills.
-Proper
Housekeeping
cannot be done due
to too many powder
leakages from
machines.
- Floors is also not
free of boxes,
swarfs, off-cuts &
other trip hazards,
hidden by powder
wastage.
- No designated
walking and driving
path and no
designated area to
place pallets and do
compacting and
blowing of end
product available as
lines cannot be
drawn on the floor.

Slip, Trip and
Fall which can
lead to minor
bump or
abrasion on
body parts

PPE:
- Safety Helmet (Not
strapped under chin)
- Safety Boots are in good
condition

-Current Housekeeping
Schedule is done once a
week. Current Schedule is
not sufficient to clear the
powders from pathway and
making it impossible to draw
lines on the pathway to
segregate walkway,
driveway and designated
area to compact and blow
end products.
4 2 8

36
3 Type: Safety
Hazard
Classification:
Work Environment
- Fall, Trip & Slip
(Physical Hazard)
– Kaolin Powder
wastage
accumulating on
floor mix with rain
water
Description:
- Slip, Trip and Fall
due to wet and
muddy floor
surfaces which will
be slippery
especially during
rainy season or
when there is liquid
spillage on floor.
- Uneven Patches
will make the Trip
Hazard more prone.
- Accumulated
powder on floor
will make mud
formation easily
formed.
- Mud will also
clump to safety
boot's sole which
would lead to slip,
trip and fall.
Slip, Trip and Fall.
Minor bruises or
scratches on body
parts.
PPE used
- Safety Boots (anti-skid).
Worker Boots is in good
condition.
- Housekeeping - once a week.
Done manually by worker
using shovel and bin.
3 2 6

37
4 Type: Safety
Hazard
Classification:
Manual Handling -
Lifting, Carrying,
Repetitive
Movements
- Paper and Wood
Material
Description:
- Repetitive contact
with rough wood
surfaces on pallets
and paper fiber
from paper bags
when doing bag
arrangements on
pallets, blowing of
powders from bags
and wrapping of
load.
Cuts on fingers
Splinters
penetration on
fingers and hands
Callus formation
PPE used: Cotton glove (but
operator does not use due to
not comfortable)
4 1 4

38
5.3 Rational for Selections of Critical Hazards
5.3.1 Critical Safety Hazard selection
Hazard Type : Safety Hazard
Hazard Classification : Mechanical - Vehicles
Source : Forklift Truck Overturns due to due to uneven surfaces and
unsecured and unstable Load while manoeuvring
Consequence or Impact : Fatality or Permanent Injury
1. Operator Slip and Fall out from Forklift Truck onto the ground.
2. Worker body parts (Feet, arm, head) may be crushed and broken by Forklifts when it
overturns to the side.
3. Worker may also suffer from bruises or scratches on body parts.
Existing Risk Control :
1. Elimination - NIL
2. Substitution - NIL
3. Engineering Control- NIL
4. Administrative Control -
i. PPE Inspection FY2018 at P1, conducted in 01 February 2018 focused on the
condition and availability of Safety Shoe / Boots, Safety Helmet, Hand Gloves
and Face Mask/ Shield.
ii. Training "Tractors Material Handling: CAT Lift Truck Operator Safety Training"
conducted by CAT Lift Trucks on 03 January 2018 at P1 for Forklift Drivers.
iii.Maintenance and repair contract with multiple Forklift Truck suppliers. The
management has engaged new suppliers who are proactive in supporting the

39
reduction of down time due to forklift damages or failures. The suppliers are
UMW (Hire-purchased) and CAT Lift Trucks (Rental).
iv. WhatsApp Group Chat has been created since 06 September 2017 to monitor
Forklift condition and to report any damages, breakdowns and misused. Person
In Charge of Forklift matters has been appointed. Manager - Ng Soe Jean,
Coordinator - Gnanapragasam.
v. WhatsApp Group Chat has been created since 18 April 2017 for KM OSHE
Committee to report any OSHE Incidents and delinquents at the organization.
Employees who do not use their PPE while at work will have their pictures taken
and posted in the group immediately. Penalty will be imposed on the wrong
doers caught by HR.
5. PPE -
i. Safety Helmet - Brand: Proguard, Model: HG1-PHSL, Description: ABS Shell
with Slide Lock System, chinstrap and sweatbands. Provided by company at
Admin Office upon commencement of contract.
ii. Safety Boots - Company provided monthly allowance of RM50 to operator to
purchase own safety boots. No specific requirements implemented for Safety
Boots.
The Qualitative Method of Relative Risk for this Risk Matrix is 12, which is MEDIUM in the
Risk Matrix Table. A Medium Risk requires a planned approach to controlling the hazard and
applies temporary measure if required. Actions taken are required to be documented on the
risk assessment form with date of completion.

40
Severity of Hazard, Rate = 4
The Severity of this hazard is rated 4 in the Severity Table, which indicates that the hazard is
Fatal if the gravest form of injuries is being realized. There is approximately 1 single fatality
expected from it. The decision is derived after taking into consideration of the governmental
bodies reports over the years and reviews on the organization in-house records as per below:
i. Department of Safety and Health Malaysia, Fatal Accident Case Report , Last
Modified: 07 May 2018
The table below shows the total fatal accident cases recorded caused by overturned
forklift in Malaysia throughout the years (2014 - 2017). For each year, at least 1 fatality
was recorded. The deceased victims suffered from serious injuries and severe bleeding to
the head, internal body injuries, injuries to the neck and back and broken hip-bone. The
victims were pinned, struck or crushed by the overturned forklift. Recorded observations
shows that the victims did not undergo forklift driving and handling training, is not
qualified to operate the forklift, no safe work procedure in organization and poor work
environment due to uncontrolled weather condition.
ii. Factories and Machinery (Electric Passenger and Goods Lift) Regulations 1970
The Factories and Machinery Act 1967, Malaysia was revised 1974 to include
mechanical handling equipment use for moving, lifting shifting and transferring of loads
or goods such as forklift to comply to the regulations. Forklift does not require Certificate
of Registration with the Department of Safety and Health, Malaysia. However, DOSH
requires employer to come up with a Safe Work System for safe handling of forklift at
the workplace.

41
DOSH Fatal Accident Case
Date Title Case Location Summary Case
Contributing
Factors
Observation
10-02-
2017
Died being
pinned by
forklift
Factory,
Sarawak
An overturned forklift hit the
driver due to failed making a U-
turn
Serious injuries to
the head
1) forklift was not in
proper condition to be
used
2) Victim did not undergo
forklift driving training
14-05-
2016
Died being
struck by
forklift
Port, Johor
Prior to the incident, the victim
was driving the forklift out of
the truck. Suddenly, the rear tyre
slip off the ramp lead the forklift
to overturned. He jumped off
but unfortunately forklift fell on
him. He died at the hospital
Internal injuries
17-12-
2015
Died being
struck by
forklift
Quarry sites,
Sabah
The accident occurred as the
victim driving forklift down the
hill. The vehicle suddenly out of
control causing it to overturned.
The victim was pinned under the
forklift
serious injuries to
the neck and back
Slippery road conditions
30-01-
2015
Died by
forklift
accident
Material
Storage,
Pulau
Pinang
Prior to the incident, alleged
victim was driving a forklift. No
witnesses at the scene. Victim
was found lying on the ground
with the forklift overturned
Bleeding in the
head
09-09-
2014
Died being
crushed by
forklift
Construction
site, Pulau
Pinang
The unbalanced forklift driven
by the victim has caused it to
overturned and crush the victim
Severe bleeding in
the head
26-06-
2014
Died being
pinned by
forklift
Rice
Milling,
Perak
Forklift overturned and crash the
driver while carrying work of
lifting and placing jumbo bag
Broken hip bone
-No safe work procedure -
Victim has never
undergone intensive
training regarding to
forklift handling
22-05-
2014
Died crushed
by forklift
Factory,
Kuala
Lumpur
Forklift overturned and fell on
top of the victim.
Serious injuries to
the head
Victim is not qualified to
operate the forklift
OSH INFO
Copyright @ 2016 Department of Occupational Safety and Health Malaysia. All Rights Reserved. | Best Viewed
1280 x 1024 with Internet Explorer 9.0, Mozilla Firefox 3.0, Chrome and Safari.
Last Modified: 07 May 2018

42
Likelihood of Hazard, Rate = 3
The Likelihood of Occurrence for this Hazard is rated 3 in the Likelihood Table, which
indicates that the hazard is Conceivable to occur. Although the Severity Rating is High, the
Likelihood of the event to at some time in the future can be justified by the events below:-
i. Existing Risk Control
The management has been taking serious notice of the forklift truck due to its high
maintenance and repair cost. Currently, the management of this hazard relies heavily on
Administrative Control and implementation of Personal Protective Equipment for all
employees. There are no major or first aid casualties related to forklift truck handling in the
factory.
ii. Organization In-house Training and Inspection Records
a) Operator Name : Azmeer Hossain
Work Shift : Day Shift
Referring to the forklift training attendance list, it is noted that the Day Shift Operator,
was absent for both PPE Inspection FY2018 at P1 conducted in 01 February 2018 and
Training "Tractors Material Handling: CAT Lift Truck Operator Safety Training"
conducted by CAT Lift Trucks on 03 January 2018. However, during the Workplace
Assessment Interview with him on 20 March 2018, findings show that his safety boots
is in good working conditions (although socks were not worn).

43
b) Operator Name : Rajak Mohan Lal
Work Shift : Night Shift
Operator has attended both events, however findings on his Safety Boots condition was
bad. Safety boots needs to be replace (socks was worn). This is further confirmed during
the Workplace Assessment Interview on 20 March 2018 with him in which his safety
boots was inspected again. Feedback from operator revealed that the worker is not sure of
the requirements of a good safety boots for his workplace due to no guidelines from the
organization.
iii. Scheduled Maintenance of Forklift Trucks
Scheduled maintenance of Forklift Trucks is done daily and periodically by operator and
supplier. Reference can be found in Appendix.

44
5.3.2 Critical Health Hazard selection
Hazard Type : Health Hazard
Hazard Classification : Chemical – Toxic, Chronic
Source : Kaolin dust particulates exceeding the Permissible Exposure
Limit
Consequence or Impact : Occupational Asthma caused by particulate irritants
1. Pneumoconiosis (kaolinosis, fibrosis)
2. Confluent lesions at respiratory tract
3. Massive fibrosis in lungs which can lead to disablement
Existing Risk Control :
6. Elimination - NIL
7. Substitution - NIL
8. Engineering Control- NIL
9. Administrative Control -
vi. The latest CHRA was conducted on 04 January 2018. Report shows that dust in
Production area is currently Risk significant and not adequately controlled. Work
area is naturally ventilated. Workers are not allowed eating, drinking & smoking
inside work area.
10. PPE -
iii.N95 mask model: Safetyware 3223 (without valve). Provided by company upon
request at Admin Office.
The Qualitative Method of Relative Risk for this Risk Matrix is 15, which is HIGH in the
Risk Matrix Table. The High Risk requires immediate action to control the released of kaolin

45
dust particles to the work environment as detailed in the hierarchy of control. Actions taken
are required to be documented on the risk assessment form with date of completion.
Severity of Hazard, Rate = 3
Although DOSH Statistics for “Occupational Disease & Poisoning by Type of Disease” for
year 2016 shows that the highest number of injury is caused by Occupational Noise-related
Hearing Disorders (2876 cases) and followed by Occupational Muscular-Skeletal Disorders
(173 cases), Occupational Lung Diseases comes third in line with 98 reported cases (not
taking into accounts of 574 cases of Non-Occupational Diseases).
The Severity of this hazard is rated 3 in the Severity Table, which indicates that the hazard is
Serious as it can cause non-fatal injury and permanent disability. The decision is derived after
taking into consideration of the legal requirements and publication of report below:
i. Occupational Safety and Health Act 1994 and Regulations
Kaolin mineral is listed in Schedule I of the Occupational Safety and Health (Use and
Standards of Exposure of Chemicals Hazardous to Health) Regulations of the
Occupational Safety and Health Act 1994 and Regulations. Kaolin mineral is listed as a
Chemical under the CAS No. 1332-58-7. The allowable Permissible Exposure Limit
(PEL) within the Eight-hour Time-weighted average airborne concentration is less than
2mg/ m3
for particulate matter containing no asbestos and <1% crystalline silica
(respirable fraction).

46
ii. Factories and Machinery (Mineral Dust) Regulations 1989
Kaolin is listed in Schedule of the Factories and Machinery (Mineral Dust) Regulations
1989 of the Factories and Machinery Act, 1967. Permissible Exposure Limit (containing
free silica less than 1% in weight) is at a concentration greater than 5 milligrams per
meter cube of respirable dust or 10 milligram per meter cube of total dust averaged over
an eight-hour period. Crystalline silica exposed to an employee shall less than 0.1mg per
meter cube of respirable quartz.
iii. World Health Organization Geneva, 2005 Report
Report Name : Environmental Health Criteria 231
Description : BENTONITE, KAOLIN, AND SELECTED CLAY MINERALS
A WHO Task Group on Environmental Health Criteria for Bentonite, Kaolin, and
Selected Clay Minerals met at Bradford University, Bradford, United Kingdom, from 18
to 22 October 2004 to publish a report containing the collective views of an international
group of experts (that does not necessarily represent the decisions or the stated policy of
the United Nations Environment Program, the International Labour Organization, or the
World Health Organization).
The Report Summary of “Evaluation of Kaolin on human health risks and effects on the
environment” conclude that:
a. Long-term exposure to kaolin may lead to a relatively benign pneumoconiosis,
known as kaolinosis. Deterioration of lung function has been observed only in cases
with prominent radiological alterations. Based on data from china clay workers in the

47
United Kingdom, it can be very roughly estimated that kaolin is at least an order of
magnitude less potent than quartz. Its fibrogenic potential is considered to be at least
an order of magnitude less than that of quartz.
b. Kaolin that contains quartz, which is known to cause silicosis and lung cancer.
c. The biological effects of clay minerals are influenced by their mineral composition
and particle size. The decreasing rank order of the potencies of quartz, kaolinite, and
montmorillonite to produce lung damage is consistent with their known relative
active surface areas and surface chemistry.
Likelihood of Hazard, Rate = 5
The Likelihood of Occurrence for this Hazard is rated 5 in the Likelihood Table, which
indicates that the hazard is Most Likely to occur. The most likely result of the hazard/
event being realized can be justified by the events below:-
i. Nature of Company Business and Operations
The main business in this factory revolves around kaolin mineral. The mineral is found in
abundance in all work areas. Other than the processing and refinement of kaolin clay, the
most important final steps of kaolin production is centralized at the production line, thus
making it a critical work hazard which is impossible to avoid.
The duration of exposure to kaolin dust particulate for the each shift operator is
maximum 11 hours daily. The Human Resource design the operator’s salary as Incentive
base, according to the tonnage produced. On average, the operator is able to produce 9

48
Metric Tonne of products per shift, subjecting each operator to manually handle an
average of 360 bags of kaolin powder daily.
The Health Hazard trail can be described as per below:
1. Paper Bag is swollen due to the air filling the bag.
2. The air will push the access powder out from the bag when it reaches 25kg weight,
causing powder spillage to occur.
3. Concurrently, due to the abrupt force of auto-cut function of the Valve Packing
Machine, powder will also spill out from the valve’s nozzle.
4. The dust particulate from both spillages will be released to environment within the
Operator’s breathing zone.
5. Other dust particulate sources released to same work environment are leakages from
Vibrating Screen, KM Separator and Reject Powder Machines at IDX.
6. Operator inhales the kaolin dust particulate.
ii. Previous Monitoring Report by Competent Person
a) Chemical Exposure Monitoring conducted by Hygiene Technician Type 1 on 08 –
09 October 2014. Personal Exposure Monitoring result showed that contaminant
concentration of Inhalable Particulate, Respirable Particulate and Crystalline Silica
(Quartz) in IDX are well within their respective Permissible Exposure Limit (PEL) –
8hrs TWA Exposure Limit as specified in Occupational Safety & Health (Schedule I
of USECHH) Regulation 2000 and Factory & Machinery (Mineral Dust) Regulation,
1989.
b) Dust Exposure Monitoring conducted by Hygiene Technician on 26 June 2004.

49
The discussion showed that:-
i) the results of the personal exposure sampling showed that there are high risk
dusty areas in the plant, which is Production Area (but did not specifically
identified which area)
ii) the personal dust exposure monitoring has confirmed that “packer” (but did not
specifically identified packer for which production area) are exposed to dust
level exceeding the stipulated permissible Exposure Limit (PEL) of 2mg/m3
of respirable dust averaged over an 8 hour period.
Conclusion of the report indicated that there is no Respirable Quartz detected in the
Respirable Dust sampled.
iii. Existing Risk Control
Taking into account of the existing Risk Control for this Health Hazard, Operator is wearing
PPE, N95 Mask as per advised by Chemical Health Risk Assessor (CHRA) on 17 December
2014. Brand and Model of the N95 mask is Safetyware 3223 (without valve). It is noted that
Operator does not devotedly use the mask provided due to lack of enforcement management.
Feedback from Interview with operator revealed that mask is uncomfortable and stuffy. It also
gets dirty easily.
Referring to the subsequent CHRA conducted on 04 January 2018, assessment showed that
dust in IDX Production area is still Risk significant and not adequately controlled. However,
other things to be noted is that impact through ingestion will not occur as Operators are not
allowed to eat, drink and smoke within the work area.

50
5.4 Impact of Critical Safety and Health Risks identified to the Organization.
Identified hazards should be controlled to prevent accidents and occupational diseases. When
not controlled adequately, the accidents will have a negative impact on both employer and
employees of the organization. The organization shall reflect a non-people-friendly and safety
oriented management that does not prioritize a secure work system.
The impact of the identified hazard to the company can be divided into 2 categories, which is
Direct Impact and Indirect Impact. Direct impact can be seen on damages to employees,
environment and property assets. It can lead to increase of medical cost or losses in
investment and profit. Indirect Impact can procure prolong liabilities due to damage company
reputations which may lead to loss of procuring future clientele contract and businesses.

51
Direct Impact to Organization
Hazard Potential Accidents Consequences Cost Incurred
Safety Hazard,
Mechanical
Hazard,
Forklift Truck
overturns
Employees  Operator Slip and Fall out
from Forklift Truck onto the
ground
 Operator body parts (Feet,
arm, head) may be crushed
by Forklifts when it overturn
to the side
Physical:
 Fatality or Permanent
Injury
 crushed and broken body
parts
 Bruises or scratches on
body parts.
Psychologically:
 Trauma
 Emotional & Mental stress
 Loss time injury
 Cost of repatriation of victims
 Cost of acquiring replacement
worker
 Medical & Hospitalization Cost
 High insurance cost
 Fine or Compound by regulated
bodies - DOSH, Labour Law,
PERKESO
Environment  Leakages of lubricant to
ground from overturn
Forklift
 Leakages of powders from
broken bags to soil and air.
Air, Water and Soil Pollution  Fine or Compound by regulated
bodies - DOE
 Cost to clean the Environment
Assets  Damage to floor, wall or
warehouse structure
 Damage to Forklift Truck
 Damage to finished goods
 Cost to repair damage Forklift
 Loss of cost of damage
products

52
Hazard
Potential
Accidents
Consequences Cost Incurred
Health Hazard,
Chemical,
Chronic
Toxicity,
Kaolin Dust
Particulate
exceeding PEL
Employees Operator
exposed to
kaolin dust
particulates
exceeding the
Permissible
Exposure Limit
set by
regulation
bodies
Physical:
Occupational Asthma caused by particulate
irritants
 Radiological Pneumoconiosis (kaolinosis,
fibrosis)
 Confluent lesions in respiratory tract
 Massive fibrosis which can lead to
disablement
Psychological:
 low motivation to come to work
 excuse to not come to work
 no loyalty and love for the company
 Medical & Hospitalization Cost
 Cost of Health Surveillance
 Reparation cost
bodies - DOSH DOE
Environment uncontrolled
released of
wastage to the
environment
 Air, Water and Soil Pollution
 Affects general public Psychologically:-
 anger
 irritation
 aggressive
 Disruptive to surrounding businesses.
Spoil or contaminate other businesses
products
 Regulated body may lock up production
equipment
bodies - DOE
 Cost of Correcting Machines
 Cost to clean the Environment
 Compensation to other
businesses due to damage of
others goods.
Assets Damages is hidden by accumulating powders On time and swift maintenance
cannot be conducted

53
Indirect Impact to Organization
Potential
Accidents
Consequences of Accidents Impact on organization Impact on colleagues
Impact to worker’s
family
Safety Hazard,
Mechanical
Hazard,
Forklift Truck
overturns
Operator Slip and
Fall out from
Forklift Truck
onto the ground
Operator body
parts (Feet, arm,
head) may be
crushed by
Forklifts when it
overturn to the
side
Physical:
 Fatality or Permanent
Injury
 crushed and broken
body parts
 Bruises or scratches on
body parts.
Psychologically:
 Trauma
 Emotional & Mental
stress
1- Negative press and public review due
to incidents caused by poor safety
and health at workplace
2- Company’s image (major supplier) is
affecting customer’s image
3- Customer loses trust and become
source of failure to secure future
contract
4- Lost of other new contact as most
big clientele require compliance to
OSHA
5- Unable to secure fair price for
product to generate higher profit
income
6- In the case where fatality occur,
production has to be stopped for
police investigation
7- Legal action against organization
8- Compensation costs to the victimized
worker
1- Motivation
decreased due to
colleague’s
demised
2- Decrease in salary
due to halt in
production
3- Additional
workload due to
loss of manpower
4- Psychologically
disturbed:
 Trauma
 Emotional &
Mental stress
1- Victim family is
unhappy and will
push for
explanation as
soon as possible
2- Lost of source of
income
3- Victim’s family
experience
emotional stress

54
9- high worker turn-over due to unsafe
work environment
10- Cost for hiring process and sourcing
for labour will never decrease
11- Cost for sending new worker for
competency training
12- worker competency and maturity in
the industry will never increase
13- new-edge products, patents and
trademarks cannot be developed
2- Health Hazard,
Chemical,
Chronic Toxicity,
Operator exposed
to kaolin dust
particulates
exceeding the
Permissible
Exposure Limit set
by regulation
bodies
Physical:
Occupational Asthma
caused by particulate
irritants
 Radiological
Pneumoconiosis
(kaolinosis, fibrosis)
 Confluent lesions in
respiratory tract
 Massive fibrosis which
can lead to disablement
Psychological:
 low motivation to come
to work
 excuse to not come to
work
no loyalty and love for the
company

55
6.0 RECOMMENDATION
Control is the elimination or inactivation of a hazard in a manner such that the hazard does
not pose a risk to the workers who have to enter into an area or work on equipment in the
course of scheduled work.
Hazard should be controlled
at their source where the
problem is created. The
closer a control is to the
source of hazard; the better
the hazard can be managed.
This method is often referred
to as Engineering Controls.
If this does not work, hazards
can often be controlled along the path to the worker, between the source and the worker.
This method can be described as Administrative Controls.
If this is not possible, hazards must be controlled at the level of the worker through the use
of personal protective equipment (PPE), although this is the least desirable control.
Selection of control often involves evaluation and selection of short and long term controls
Implementation of short term controls is for the purpose of protecting worker until
permanent controls can be put in place. Implementation of long term controls is done when
it is reasonably practicable.

56
Information for control measures of hazards can be derived from:-
a. Industrial Code of Practice (ICOP)
b. Product Safety Data Sheet
c. Forklift Truck Operation Manual
d. Rules and Regulations set by regulatory bodies - DOSH, DOE and Malaysian Labour
Law
e. Authorized Books and Research papers Publications on mentioned hazards

57
6.1 Safety Hazard Proposed Control Measures
Hazard Type : Safety Hazard
Hazard Classification : Mechanical - Vehicles
Source : Forklift Truck Overturn due to uneven surfaces and unsecured
and unstable Load while manoeuvring
Consequence or Impact : Fatality or Permanent Injury
1. Operator Slip and Fall out from Forklift Truck onto the ground.
2. Worker body parts (Feet, arm, head) may be crushed and broken by Forklifts when it
overturns to the side.
3. Worker may also suffer from bruises or scratches on body parts.
Control Existing Risk Control Proposed Risk Control
Elimination NIL Preventive Control:
 Elimination of the use of Forklift
Truck
Corrective Control:
 Repair all uneven surfaces, cracks
& potholes on forklift pathways.
Substitution NIL Preventive Control:
 Substitution on worker with robots
 Use Robotic Arms and Automation
Packing to transfer bags to pallet
and warehouse instead of using
Forklift truck
Engineering
Control
NIL Preventive Control:
 Substitution of traditional concrete
flooring to Industrial Epoxy
Flooring
 Redesign job and processes to make
it safer. No mobile transportation
needed from packing area to
warehouse store. Transportation can
be done using conveyor belt system
directly from packing area to
warehouse store.
 use machine automation which can
straight away compact, strap,

58
shrink-wrap and storage of finished
goods in warehouse after packing
completed.
Administrative
Control
i. PPE Inspection
ii. Training on Forklift
Handling
iii. Maintenance and repair
contract with multiple
iv. WhatsApp Group Chat -
Proactive report on Forklift
condition
v. WhatsApp Group Chat -
KM OSHE Committee
OSHE Proactive Incidents
and delinquents report and
notification.
vi. Penalty imposement by HR
Corrective Control:-
 Review current “Vehicle Operation
Safety Procedure” together with
workers and implement it. Use Job
Safety Analysis Techniques.
 Patch existing potholes and cracks
and smoothen and lowered uneven
surfaces.
Preventive Control:-
 Create training schedule which
include new workers.
 Provide refresher training for old
workers
 Workplace Audit by OSHE
Committee to ensure workplace is
floor is free from potholes, cracks
and uneven surfaces
 Periodic maintenance on floor to
cover or repair potholes, cracks and
uneven surfaces at work area
 Create clear lines and a safe
boundaries between pedestrian and
driving pathways.
 Warning signage on speed limit
especially at turning points
 Install speed bumps before
dangerous turnings
 Follow load limit of mobile
equipment set by supplier. Refer
Operation Manual for guidelines.
 Travel on inclines forward with
load uphill. Travel down inclines in
reverse with load facing forward
 To place signage at workplace on
required PPE for that area
 Regular schedule housekeeping at
workplace

59
Personal
Protective
Equipment
i. Safety Helmet - Brand:
Proguard, Model: HG1-
PHSL, Description: ABS
Shell with Slide Lock
System, chinstrap and
sweatbands. Provided by
company at Admin Office
upon commencement of
contract.
ii. Safety Boots - Company
provided monthly
allowance of RM50 to
operator to purchase own
safety boots. No specific
requirements implemented
for Safety Boots.
Corrective Control:
 Safety Helmet must be strapped and
in good condition
 Operator to use seatbelt when
driving forklift
Preventive Control:
 To provide guidelines of Safety
Boots functional characteristic
requirements.
 To provide recommendations of
approved Safety Boots brand and
model and approved supplier
contacts
 To provide training on care of PPE
 To provide awareness training on
function of PPE

60
6.2 Health Hazard Proposed Control Measures
Hazard Type : Health Hazard
Hazard Classification : Chemical – Toxic, Chronic
Source : Kaolin dust particulates exceeding the Permissible Exposure
Limit
Consequence or Impact : Occupational Asthma caused by particulate irritants
1. Pneumoconiosis (kaolinosis, fibrosis)
2. Confluent lesions at respiratory tract
3. Massive fibrosis in lungs which can lead to disablement
Control Existing Risk Control Proposed Risk Control
Elimination NIL NIL
Substitution NIL Preventive Control:
i. Substitution of packing operator with
robotic hands
Engineering
Control
i. Work area is naturally
ventilated
Preventive Control:
i. Isolation of machinery from worker –
air conditioned room with local
exhaust ventilation at source of
hazard (valve packing machine)
ii. containment of dust using dust by
installing bag filter system,
scrubber system and local exhaust
ventilation to ensure dust does not
escape to worker breathing zone
and to workplace environment
iii.Wall barrier to segregate packing
area and machines to isolate worker
from dust exposure
iv. To redesign the work area using
automization bagging system and
robots
Corrective Control:
i. To cover all leakages at machines
emitting out dust

61
Administrative
Control
i. Workers are not allowed
eating, drinking &
smoking inside work
area.
Preventive Control:
i. Conduct Medical Surveillance on
worker
ii. Create warning signage of side
effects of kaolin dust to health and
list down the compulsory PPE to
use when handling mineral. .
iii.Make SDS available at work area for
workers to read.
iv. To conduct schedule Chemical
Exposure Monitoring by competent
person
v. Emergency Evacuation Plan when
release of dust
vi. Posters at work area to remind
worker of hazard exposure
vii. Warning signage at work area to
remind worker of required PPE for
the work area
viii. Provide training on product hazard
and refresher training for old
workers
ix. First Aid measures to treat hazard if
worker is over exposed
Corrective Control:
5.4 Impose penalty on workers who do
use PPE
Personal
Protective
Equipment
i. N95 mask model:
Safetyware 3223
(without valve).
Provided by company
upon request at Admin
Office.
i. Provide N95mask Model Safetyware
3223 (with Valve) for more
comfort. Mask must be disposed
when not functioning.
ii. Provide half-face silicon Respirator
fitted with filter cartridge (reusable,
better hygiene and cost saving)
Current mask is Not adequate,
because work area is too dusty and
require frequent change of mask to
ensure efficiency
iii.Wear safety goggles or face shield
when handling chemical to avoid
chemical splash into eye. Currently
no protection worn to protect skin
& eyes from chemical exposure.
iv. Training on how to clean and
maintain mask
v. Awareness training on function of
mask

62
In the Occupational Safety and Health (Use and Standards of Exposure of Chemicals
Hazardous to Health) Regulations, Part VII, Regulation 25 – “Provision of Chemical Safety
Data Sheet in a place of work” requires that the copy of Safety Data Sheet of chemical
hazardous to health be kept in a conspicuous place close to each location where the chemical
is used, and shall be easily accessible to the employees.
6.4 Explanation on the proposed review program on the effectiveness of the proposed
control measures in subsection 6.1 and 6.2.
Review of control measures is important to ensure its effectiveness. Control measures should
also be in accordance with the requirements of this legislation to be ensured because it can
reflect the effective management system and legal aspects are not neglected. Some of the
steps that can be adapted are
1) Safety and health audits
Periodic audits can review the effectiveness of the control measures. If referring to a
formal audit of the recognized security management system certification body needs to
be adapted. Examples of security management systems are OHSAS 18001. This may be
the future management's consideration.
2) Accident reporting
 Every incident / accident occurring at the workplace should be recorded. By checking the
crash report, the level of effectiveness of control measures can be identified. If the level
of effectiveness is low, the more effective control measures need to be introduced
 Accident reports can be reviewed by the safety and health committee. The committee
reserves the right to determine whether additional control measures are required. When

63
the committee meets (once every 3 months) the discussion of the effectiveness of the
control method can be an agenda.
6.4 Discuss the benefits of the recommendations in subsection 6.1 and 6.2 to the
organization.
There are numerous benefits to the company from all the control measures proposed in 6.1
and 6.2. Among them, workplace safety can be enhanced by effective control measures. When
all control measures are taken comprehensively, workplace accidents can be prevented.
Employees will also be more careful while working and trying to avoid accidents. Therefore,
the number of accidents or incidents can be reduced.
As a result of this, the company may reduce or avoid the costs of medical and hidden costs
due to lack or unnecessary accident at the workplace.
In addition, the use of time and workforce can also be reduced. This is due to lack of or no
postponement and termination of work due to unemployment in the workplace.
In the meantime, employees will be able to work more comfortably without worrying about
their safety and health. With that, productivity and quality can be improved over time.
Finally, the image of an organization or company is more prominent due to the lack of
accidents, especially those that cause death and serious injuries. This will give greater input to
the organization as it will contribute to the client's confidence and trust and can cater to
competitors in the industry. This situation will benefit the company to continue to thrive.

64
7.0 REFERENCE/ SOURCES
Book Reference:
1. Guidelines for Hazard Identification, Risk Assessment and Risk Control (HIRARC),
Department of Occupational Safety and Health Ministry, Ministry of Human Resources,
Malaysia, 2008, JKKP DP 127/789/4-47, ISBN 978-983-2014-62-1
2. Occupational Safety and Health Act 1994 and Regulations, ACT 514, Published and
Printed by MDC Publishers SDN BHD, Published and Printed in January 2016
incorporating all amendments made up to January 2015, ISBN 978-967-70-1460-9
3. Factories and Machinery Act 1967, ACT 139,Published and Printed by MDC Publishers
Sdn Bhd, Published and Printed on January 2017 incorporating all amendments made up
to August 2015, ISBN 978-967-70-1459-5
Competent Person Reports on Organization
1. Initial Noise Exposure Monitoring for Company Industrial Minerals Sdn Bhd
(pseudonym), conducted by KenEp Resources (Asia) Sdn Bhd under Factories and
Machinery (Noise Exposure) Regulations 1989, Date monitored: 17th
November 2014,
Report No.: KAO/KR-DOSH1214/748/SY.
2. Initial Personal Chemical Exposure Monitoring Report for Company Industrial
Minerals Sdn Bhd (pseudonym), conducted by KenEp Resources (Asia) Sdn Bhd under
Occupational Safety and Health (Use and Standards of Exposure of Chemical Hazardous
to Health) Regulation, 2000 and Factories and Machinery (Mineral Dust) Regulations,
1989; Date monitored: 08-09 June 2014, Report No.: KAO/KCS-KR-DOSH0115/757/SY.

65
3. Mineral Dust Exposure Monitoring at Company Industrial Minerals Sdn Bhd
(pseudonym), conducted by Envirotech Consultancy Services under the OSHA 1994
USECHH Regulation, Date monitored 26 June 2004
4. Chemical Health Risk Assessment Report, conducted by KenEp Resources (Asia) Sdn
Bhd under Occupational Safety and Health (Use and Standards of Exposure of Chemical
Hazardous to Health) Regulation, 2000, Date conducted: 17 December 2014
5. Workplace Safety, Health and Environment Audit Report, conducted by KenEp
Resources (Asia) Sdn Bhd, Date conducted: 27 August 2015
Online Government Bodies Statistics Reports
1. Fatal Accident Case, Department of Occupational Safety and Health, Ministry of Human
Resources Malaysia, http://www.dosh.gov.my/index.php/en/fatal-accident-case
2. Occupational Diseases and Poisoning Investigation, Department of Occupational Safety
and Health, Ministry of Human Resources Malaysia,
http://www.dosh.gov.my/index.php/en/occupational-diseases-and-poisoning-statistic
3. Safety Alert, Occupational Diseases and Poisoning Investigation, Department of
Occupational Safety and Health, Ministry of Human Resources Malaysia,
http://www.dosh.gov.my/index.php/en/safety-alert2
4. https://youtu.be/dNaCb5H7TFc
5. Statistics (SOCSO), Occupational Diseases and Poisoning Investigation, Department of
Occupational Safety and Health, Ministry of Human Resources Malaysia,
http://www.dosh.gov.my/index.php/en/osh-info-2/occupational-health/398-statistics-
socso

66
6. Struck by falling object, Cause of Accidents, Occupational Respiratory Diseases,
Table 5: Number of Accidents and Benefit Paid According to Cause of Accident and
Gender, Annual Report FY2016 PERKESO, Social Security Organization, Malaysia.
7. Means of Transport and Lifting Equipment, Agent causes, Table 9: Number of
Industrial Accidents and Benefit Paid According to Agent Causes and Gender, Annual
Report FY2016 PERKESO, Social Security Organization, Malaysia.
8. Occupational Respiratory Diseases, Disease by target organ system, Table 10: Number
of Commuting Accident and Benefit Paid According to Agent Causes and Gender,
Annual Report FY2016 PERKESO, Social Security Organization, Malaysia.
9. World Statistic, International Labour Organization (ILO),
http://www.ilo.org/moscow/areas-of-work/occupational-safety-and-
health/WCMS_249278/lang--en/index.htm
Online Publications, Statistics and Reports
1. ENVIRONMENTAL HEALTH CRITERIA FOR BENTONITE, KAOLIN, AND
SELECTED CLAY MINERALS, Published under the joint sponsorship of the United
Nations Environment Programme, the International Labour Organization, and the World
Health Organization, and produced within the framework of the Inter-Organization
Programme for the Sound Management of Chemicals; World Health Organization
Geneva, 2005; http://www.inchem.org/documents/ehc/ehc/ehc231.htm
2. How to Prevent Musculoskeletal Disorders (MSDs) in Manual Material Handling
Environments; http://ergo-plus.com/prevent-musculoskeletal-disorders-msds-manual-
material-handling-environments/

67
3. COMMON CAUSES OF FORKLIFT ACCIDENTS, Forklift Exchange, Posted on July
4, 2017 by forklift https://forkliftexchange.co.za/common-causes-forklift-accidents/
4. Heat Stress, National Institute of Occupational Safety and Health, Education and
Information Division, Published July 30, 2015;
https://www.cdc.gov/niosh/topics/heatstress/default.html
5. Occupational Safety And Health (Classification, Labeling And Safety Data Sheet Of
Hazardous Chemicals) Regulations 2013 [P.U.(A) 310/2013]
http://www.dosh.gov.my/index.php/en/main-slide-banner/348-osh-info/chemical-
issues/994-occupational-safety-and-health-classification-labelling-and-safety-data-sheet-
of-hazardous-chemicals-regulations-2013-p-u-a-310-2013
6. Effective Workplace Inspections, Canadian Centre for Occupational Health & Safety,
Date modified: 2018-05-25, http://www.ccohs.ca/oshanswers/prevention/effectiv.html
7. Job Safety Analysis, Canadian Centre for Occupational Health & Safety, Date modified:
2018-05-25, https://www.ccohs.ca/oshanswers/hsprograms/job-haz.html
Websites Referral
1. POLIMAT® series palletizer, FLSmidth Ventomatic,https://youtu.be/oTDLRR17fqI
2. Wood pellet bagging line with robot up to 1400 bags / hour. Elocom S.L
https://youtu.be/pb_KAI9-03k
3. 25KG kraft paper bag packing machine, Fully automatic, high speed,
http://en.zengran.com.cn/Product_00030017.html, https://youtu.be/ZlYoJkRSYP8
4. BAGGING MACHINE - IGF 600, Concetti, Fully Automatic Bag Filling and Closing
System for preformed open mouth bags special design for PP-woven bags up to 600bph,
https://youtu.be/tiL8PkKWveg

68
8.0 APPENDICES
(Report such as figure, questionnaire, diagrams, reports, pictures, questionnaire etc.)

69
FACTORY LOCTION MAP AND IMAGES

INDIRECT HEAT X
OPERATOR WORK INFORMATION

List of Workers Updated: 01 March 2018

INDIRECT HEAT X (IDX)
PRODUCTION INFORMATION

SUMMARY OF DAILY PACKING
(FINISHED CARGO ONLY)
Production Line Jan-18 Feb-18 Mar-18 Apr-18 May-18 Jun-18 Jul-18
P1-IDX 487.40 482.20 217.45 0.00 0.00 0.00 0.00
TOTAL PRODUCTION 1540.40 1761.75 598.35 0.00 0.00 0.00 0.00
Median 358.50 412.10

HAZARD INDETIFICATION
RAW DATA

METHOD 1: Workplace Inspection - Interview with Worker

METHOD 3: Hazard Analysis - Job Safety Analysis

METHOD 2: Workplace Inspection - Workplace Audit Inspection

GOVENRMENT BODIES
STATISTICS AND DATA

DOSH Fatal Accident Case
Contributing
Factors
Observation
10-02-
2017
Died being
pinned by
forklift
Factory,
Sarawak
An overturned forklift hit the
driver due to failed making a U-
turn
Serious injuries to
the head
1) forklift was not in
proper condition to be
used
2) Victim did not undergo
forklift driving training
02-05-
2017
Died being hit
by oil tank
Warehouse,
Sarawak
A supervisor was hit by oil tank
lifted by a forklift
Serious injuries to
the head
10-05-
2015
Died being
caught in
lorry's cabin
Warehouse,
Kedah
The victim was a truck driver
died after getting trapped in the
cabin of the truck crushed by
container
serious bodily
injury
Death accidents forklift
09-09-
2014
Died being
crushed by
forklift
Construction
site, Pulau
Pinang
The unbalanced forklift driven
by the victim has caused it to
overturned and crush the victim
Severe bleeding in
the head
02-11-
2014
Died being run
over by
forklift
Cold
storage,
Selangor
The incident took place in the
cold room while the loading and
unloading works is in progress.
The victim suddenly entering
the room to move the box
containing foods and at the same
time forklift was moving
backward after lifting
the ?Container?. As a result,
victim was struck by that
moving forklift. He died on the
scene
Serious injury to
the head
Less supervision
30-01-
2015
Died by
forklift
accident
Material
Storage,
Pulau
Pinang
Prior to the incident, alleged
victim was driving a forklift. No
witnesses at the scene. Victim
was found lying on the ground
with the forklift overturned
Bleeding in the
head
30-09-
2015
Died caught
between two
machines
Temporary
storage area,
Sarawak
During the incident, victim tried
to move the forklift using lorry
loader. Unfortunately, he was
caught between forklift and
lorry due to strong pull from the
lorry loader's boom
Internal bodily
injuries
26-06-
2014
Died being
pinned by
forklift
Rice
Milling,
Perak
Forklift overturned and crash the
driver while carrying work of
lifting and placing jumbo bag
Broken hip bone
-No safe work procedure -
Victim has never
undergone intensive
training regarding to
forklift handling
24-10-
2014
Died being
crushed by
pallet
Factory,
Johor
The incident took place during
the removal of the final product
namely tubing wrapping plastic
from stor into the container
using forklift while being
watched by the victim. At that
time, it was said that wrapping
plastic tubing which is on the
pallet has slipped and fell on the
victim
Internal injuries No safe work procedure
24-04-
2016
Died being
struck by
sacks of rice
Factory,
Pulau
Pinang
Victim, a forklift driver died
after being hit by sacks of rice.
During the incident, he was
patching a hole on the sack
Serious injuries to
the body
No supervision from the
employer
23-04-
2016
Died being hit
by forklift
Factory,
Sarawak
The victim was hit by a forklift
while walking in factory
serious injury to
the head
There was no designated
path for pedestrian in the
factory
22-05- Died crushed Factory, Forklift overturned and fell on Serious injuries to Victim is not qualified to

Contributing
Factors
Observation
2014 by forklift Kuala
Lumpur
top of the victim. the head operate the forklift
17-12-
2015
Died being
struck by
forklift
Quarry sites,
Sabah
The accident occurred as the
victim driving forklift down the
hill. The vehicle suddenly out of
control causing it to overturned.
The victim was pinned under the
forklift
serious injuries to
the neck and back
Slippery road conditions
16-10-
2015
Died being
struck by
forklift
Warehouse,
Sarawak
The victim stopped his forklift
to open the gate when suddenly
the forklift moves forward and
hit his right leg
Died due to
excessive blood
loss
The employer failed to
provide training on
forklift driver
15-02-
2017
Died being run
over by
forklift
Gas storage
area,
Sarawak
A client died being hit by
forklift at the workplace. He was
waiting for the gas cylinder to
be moved to his truck.
Serious injuries to
the body
1) Designated lane for
forklift was not provided
14-05-
2016
Died being
struck by
forklift
Port, Johor
Prior to the incident, the victim
was driving the forklift out of
the truck. Suddenly, the rear tyre
slip off the ramp lead the forklift
to overturned. He jumped off
but unfortunately forklift fell on
him. He died at the hospital
Internal injuries
Showing 1 to 16 of 16 entries (filtered from 355 total entries)
OSH INFO
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DOSH Fatal Accident Case - Electrocution
Contributing
Factors
Observation
02-
05-
2017
Died of
electrocution
Workshop,
Sarawak
A mechanic was died of electrocution as was
fixing 3 pin plug wire
Injuries to
the body
02-
08-
2016
Died due to
electrocution
Electricity
Pole No. 8,
Simpang
Issu Bangat,
Sarawak
Victim died due to electrocuted while tying
yellow phase conductor.
electrocution
Failure to
communicate between
worker
10-
12-
2015
Died due to
electrocution
Construction
sites,
Sarawak
Victim died due to electrocution as he was
fixing the socket without turning off the
generator set
Electrocution Unsafe act
12-
11-
2014
Died struck
by lightning
School,
Johor
Victim, a security guard was struck by lightning
as he was walking to the school gate
Electrocution
06-
12-
2014
Died due to
electrocution
Construction
site, Johor
The victim was died due to electrocution. He is
believed was carrying welding work in confined
space
Electric
shock
No safe work
procedure
05-
11-
2014
Died struck
by lightning
Construction
site, Johor
Victim, a flagman was struck by lightning while
performing his job controlling the traffic. He
was working in an open area
Electrocution
No lightning arrester
near the open area
02-
08-
2014
Died due to
electrocution
Private
gardens,
Johor
Victim is believed carrying works of knitting the
oil palm fruits using his aluminium poles. He?s
been electrocuted when his poles got stuck in
the transformer
Electric
shock
04-
04-
2013
Died due to
electrocution
Residential
Area - Johor
Victim was found dead due to electrocution.
Victim is believed to be in the middle of
checking the condition of lights which were
malfunctioned.
Electrocution
The employer failed
to ensure electrical
leakage currents that
caused shock to the
employee as well as
the failure of the
employee to ensure
the exact cause of the
lights' failure.
02-
12-
2013
Death due to
electrocution
Construction
Site -
Sarawak
Victim was electrocuted while doing service line
installation from a house to a utility pole.
Electrocution
Failed to do hazard
identification, risk
assessment and risk
control over the work
to be done.
03-
10-
2012
Killed in an
electrocution
accident
Factory -
Johor
Victim is believed to have died of electrocution
while performing cutting of steel structure
works.
Injury to the
arm and
waist
No safe work
procedure and
supervision
08-
08-
2011
Death due to
electrocution
Factory -
Pontian,
Johor
The victim is a 25-year old local citizen who
works as a welder with 2 years of experience.
On the day of the incident, the victim was
instructed by his supervisor to carry out cleaning
works in the Plo work area. According to
witnesses, the victim was found lying on his left
side with both of his feet on the "welding bad".
He was unconscious and his head was bleeding.
There was a portable socket and a 3-pin plug
underneath his body. The victim was rushed to
Pontian Hospital and but his death was
confirmed before he could get any treatment.
Electrocution
The victim's death is
due to electrocution
from the portable
socket that was found
underneath his body.
No proper
maintenance done to
the electric wires.
No safe work
procedure.
29-
06-
2016
Died due to
electrocution
Construction
site,
Sarawak
Prior to the incident, victim was established
telephone pole using lorry loader. The victim
was electrocuted as a lorry loader boom exposed
to live wires
electrocution
No safe work
procedure
29-
10-
Died due to
electrocution
Factory,
Sarawak
Victim died due to electrocuted while removing
creepers from stay wire
electrocution
No safe work
procedure

Contributing
Factors
Observation
2016
28-
11-
2011
Died by
electrocution
Pencawang
Pengagih
Utama -
Johor
At around 4.30 pm, the two victims were
carrying out installation works of a copper bar
onto a wall for a new grounding system. Both of
the victims were electrocuted; one of them died
while the other suffered injuries to the lower
part of the body.
Electrocution
No safe work
procedures
28-
12-
2011
Killed in an
electrocution
accident
Factory -
Sarawak
The victim, a foreign national, died of
electrocution while doing inspection works of a
water pump near a factory. The victim was
given emergency medical assistance but died
before arriving at the hospital.
Electrocution
No safe work
procedures for
electrical works
27-
05-
2016
Died due to
electrocution
Construction
site,
Sarawak
Victim suffered from electrocution as he was in
contact with the mixer lorry's body. The lorry
turned into conductor as it body touched the
power lines
electrocution
26-
05-
2014
Death by
electric
shock
Shopping
complex,
Kuala
Lumpur
The victim was electrocuted as he was doing
maintenance work
Electrocution
Unsafe working
condition
23-
06-
2015
Died due to
electrocution
Shipyard,
Sarawak
Victim died due to electrocution while doing
wiring works
electrocution
1)Electric switch box
was not properly
maintained
2)No supervision
from the employer
22-
06-
2013
Worker
electrocuted
to death
Convention
Centre
The victim may have suffered electrocution
while cutting a cable running with electrical
current causing the victims left hand to be stuck
to the cable.
Electrocution
22-
10-
2013
Died due to
electric
shock
Construction
Site - Johor
Victim was allegedly electrocuted while
cleaning the pipeline of new installed air
conditioner.
Electrocution
Work premises seems
watery and through
observation it was
found that severe
electrical wiring was
not properly
maintained and fully
inspected by a
competent person.
16-
05-
2014
Death by
electric
shock
Construction
site, Kuala
Lumpur
The victim was electrocuted as he was testing
the circuit
Electrocution
15-
08-
2014
Died due to
electrocution
Plantation,
Sabah
He died being struck by eletricity as he was
cutting the oil palm fruit
Burns on the
right and left
wrist and
other part of
the body
1. Aluminiu
m pole struck the
electrical line
2. Fail to
carried out risk
assessment
14-
10-
2011
Death due to
electrocution
Residential
Area - Kuala
Lumpur
The victim, a 28-year old local citizen died due
to electrocution while installing Unifi cables
from a Distribution Board (DB) situated on a
telephone pole to a customer's house. The victim
was later taken to Selayang Hospital for further
actions.
The victim
touched a
Tenaga
Nasional
Berhad
(TNB)
electric
cable.
No safe work
procedures

DOSH Fatal Accident Case - Poisonous Gas
Contributing
Factors
Observation
28-
03-
2016
Died due to
poisonous gas
Jetty, Sabah
The victim died after inhaling H2S gas
while transferring boxes containing fish
Toxic gas
poisoning
Fail to use
appropriate safety
equipment such as
SCBA
25-
03-
2013
Died after inhaling
toxic gas
Plant - Negeri
Sembilan
2 victims died after inhaling toxic gas
while transfering schedule wastes into
the storage.
Inhalation
of toxic gas
Inappropriate usage
of PPE

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