SAFETY MANAGEMENT AND PRACTICES ASSESSMENT OF JRJ TINSMITH WORK AND SERVICES

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A Dissertation presented to the Faculty of Industrial Engineering University of San Jose Recoletos Cebu City, Philippines

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In Partial Fulfilment of the Requirements for the Degree BACHELOR OF SCIENCE IN INDUSTRIAL ENGINEERING

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By

ANGELICA O. AGACITA September 2011

Table of contents Chapter 1 I the problem and its scope Introduction Rationale of the study Flow Chart The problem Statement of the problem Significance of the Study RESEARCH DESIGN DEFINITION OF TERMS 2 2 2 3 PAGE 1 1 1 1

II

PRESENTATION, ANALYSIS AND INTERPRETATION OF DATA

4-6

III PROPOSED OUTPUT

7-9

IV FINDINGS, CONCLUSIONS AND RECOMMENDATIONS BIBLIOGRAPHY CURRICULUM VITAE APPENDICES

10-11 12 13

1 CHAPTER I INTRODUCTION Reduction of hazards and risks can achieve productivity and growth in the industry. It does not only limit to the structure and layout of the facilities in the worksite, but as well as the rights of the employee or employer. Safety must be given priority in all aspects. Regardless of the economic level of the company, micro or macro, evaluation of its safety is a need. Nowadays, development of technology contributes to the changes in the working processes. These changes could be the factors that result to work-related injuries, illhealth and diseases. Thus, preventive measures are necessary to eliminate accidents.

RATIONALE In a sheet metal or tin industry, several hazards and risks could as well occur. The study then focuses on JRJ Tinsmith Work and Services, Safety Management and Practices Assessment.

FLOW CHART - PROCESS

SHEET METAL INSTALLATION CUTTING

FABRICATING

ARC WELDING

STATEMENT OF THE PROBLEM The aim of the study is to evaluate the safety management and practices in JRJ Tinsmith Work and Services. y y y y y y Are workers able to perform the task in a comfortable position? Are the equipments regularly serviced and maintained? Is there proper ventilation? Are their hazardous chemicals involved in the process? Is electrical equipment inspected at the workplace? Is the wearing of protective equipment implemented?

SIGNIFICANCE OF THE STUDY The significance of the study is to be able to evaluate the safety management of JRJ Tinsmith Work and Services. Safety Practices and tools in the working processes are also identified. Thus, subsequent consequences could be eliminated through implementing the corrective actions. That will be a learning tool for the management, the workers and the proponents. At the end of the study, recommendations are formulated for the development of safety management in the establishment.

RESEARCH DESIGN A letter of permission was submitted to the owner of the company. The owner approved the letter and allowed the group to conduct a study. Interview, checklist and observation of the workplace were the basis of data gathering. Photos of the workers and the workplace were also taken. The group did researches through internet and books. Recommendations about the study were also formulated.

3 DEFINITION OF TERMS Hazard The inherent potential to cause injury or damage to peoples health Risk A combination of the likelihood of an occurrence of a hazardous event and the severity of injury or damage to the health of people caused by this event. Worker Any person who performs work, either regularly or temporarily for an employer. Work related injuries, ill health and diseases Worksite Physical area where workers need to be or to go due to their work which is under the control of an employer Negative impacts on health arising from exposure to chemical, biological and physical, work-organizational and psychosocial factors at work.

4 CHAPTER II PRESENTATION, ANALYSIS AND INTERPRETION OF DATA TABULATED DATA Safety Management 1.1 Communication in Safety 1.2 Human Relations 2. Employee Safety Training 3. Safety Inspection in the Workplace 4.1 Industrial Hygiene 4.2 Personal Protective Equipment 5.1 Machine and Equipment Guarding 5.2 Mechanical Hazards 5.3 General Lay-out 5.4 Housekeeping 6.1 Lifting and Carrying 6.2 Storage 7.1 Electrical Safety 7.2 Fire Safety 8.1 Accident Investigation 8.2 Documentation YES 3 4 3 0 1 2 0 0 0 0 1 2 5 4 4 0 % 60 80 37.5 0 20 20 0 0 0 0 20 33.3 100 50 100 0 NO 2 1 5 3 4 8 4 2 2 4 3 4 0 4 0 2 % 40 20 62.5 100 80 80 100 100 100 100 80 66.7 0 50 0 100

JRJ Tinsmith Work and Services has served for 15 years. According to Juan Boquecosa, the owner, the company has been a training ground for employees who wanted to go abroad. Thus, the employees dont stay that long but he as well, served as a reference for them. The worker says that the management gives them a weekly briefing about the process in the workplace. For 15 years of existence of the company, the owner says that there havent yet any injuries happened to the workers. The result shows that 7 out of 10 (70%) applies communication and human relation in the organization. While there are 3 out of 10 (30%) says that there arent communication and human relation within the company. These include that there arent written communications provided, accessible bulletin board and workers are not recognized for a job well done. The management provides an orientation of proper working conditions, safety precautions, exposure to hazards and equipment or machine handling. Although there

is no first aid treatment orientation provided, occurring accidents in the workplace havent met yet. Safety inspection in the workplace shows that 100% didnt comply with it. Routine inspections are not conducted providing that there arent documentations and corrective actions done on the problem. Although, the workplace doesnt have any windows, the wide door serves as an open space (20%). There are 80% that do not comply the Industrial Hygiene. Showing that there is no proper ventilation, production wastes (metal strips) are not disposed properly; inconvenient layout of work area and the workplace is not cleaned or arranged after shift. Only 20% of Personal Protective Equipment are available or being used in the workplace such as face shields and gloves, while the rest (80%) of the personal protective equipment are not available. It was clearly observed that the workers do not use the dry gloves although it was made available. Machine and Equipment guarding were not present in the workplace (100%). Since the area has limited space, its not possible for an installation of machine guards and housekeeping. The tools were kept on the corners and the workers are working on a limited space. Materials were not classified and placed on containers, including that there arent proper dry gloves that are worn (80%), as presented that there is no housekeeping in the workplace. Following that there is no proper storage for the equipments, chemicals and materials (66.7%). There are cabinets and shelves that are made accessible (33.3%) but these werent enough to store the necessities. On the other hand, materials that do not react with each other are stored properly. Electrical Safety is visible in the workplace (100%). The management made sure that the electrical wirings were checked before and after doing the job. The data revealed that 50% didnt comply fire safety. This is because of the limited space that there is an obstruction in fire exit, no fire drills and smoke detectors installed. Fire extinguishers are replaced according to its expiry date. The management made sure that any accidents are to be reported (100%) immediately, but documentations about the incident are not provided. In consideration, there havent reported yet any serious issues or injuries among the workers.

5 LAYOUT OF THE WORKPLACE:

Shelves

Legend:
Metals equipments Fire extinguisher tools product

FRONT VIEW OF THE SHOP

SHOP

JRJ TINSMITH WORK AND SERVICES

INTERNET CAFE

__________________________________ T. PADILLA ST. PIER 4

__________________________________

6 PHOTOS/ DOCUMENTATIONS:

Fabricating a sheet metal using a hammer without wearing PPEs and sitting on a chair.

Layout of the workplace: Workers were not available due to special holiday.

Fire extinguisher is made available and replaced according to the expiry date.

Housekeeping problem: The tools were not properly placed in the shelves and disorganized.

7 CHAPTER III PROPOSED OUTPUT Acquiring proper ventilation would mean renovating the area that would be costly on the part of the management. Housekeeping and the implementation of wearing of personal protective equipment would be an immediate solution.

Housekeeping (cabinets)
(TOOLS) Hammer, hacksaw Legend: Welding machine Cut out metals

Unfinished product will be placed here

- Water tank / product fabricated - tools in a container or box (tool box)

- Fire extinguisher - Finished product

y y y y y y

Cabinets must be with doors Lessen the workers from 5 to 3 people to accommodate the area Tools are beside them making it accessible and placed in a tool box Unused cut out metals are to be sold in the junkshop Workers are facing each other while working; placing the fabricated product at the centre Workers must wear long sleeve if hi-vis clothing are not available.

9 Some of the following proposal of personal protective equipment are in pounds since there are no made available in the Belmont hardware. Contact information for safetyshop.com is also included as well as for the shipping through DHL.com.uk. Safety training is essential as using the personal protective equipment. Neville Clarke Philippines Inc. offers Safety Management Training in the Philippines. In particular with the topic are Safety Leadership Training or the (HSMS03) Understanding and Implementing OHSAS 18001: 2007 for the metal industry that we are taking account. Promotion fee is at 7000 Php located in Cebu. They can be contact through the site www.nevilleclarke.com for reservation.

The safety leadership training will enable an organization to control its Occupational Safety and Health risks and improve its safety performance. It will enable delegates to gain an in-depth understanding of safety management how the specification can be effectively documented and implemented.

Course Content The course combines lecture sessions covering principle and practice, together with practical sessions to allow delegates to reinforce their understanding of the concepts. The main course topics are as follows: - Introduction to Occupational Health & Safety Management - OHSAS 18000 Structure and Development - OHSAS 18001 Requirements and Implementation. - Managing an Occupational Health & Safety System Safety Shop can be contact using the following details: Full Postal Address Safety shop Douglas Bruce House Corrie Way, Bredbury Industrial Park Stockport, Cheshire, SK6 2RR England +44 161 406 5500 (International) Monday to Friday, 8:30am to 5pm

10 CHAPTER IV FINDINGS Although the layout of the company is too narrow to accommodate the 5 workers, there is no possible serious risk for electrical shocks. The management, as well as the workers, always make sure that the electrical wires are properly wired. During the observation, the workers were not wearing personal protective equipments such as dry gloves, shoes, safety glasses with sided shields under a welding helmet welding jackets and earplugs. It shows that there is a minimal protection on the metal workers. The metal workers are also subject to radiation and fumes in arc welding. Theres always been a possible hazard, apparently on the skin of the workers, such as burns and cuts. The workers arent able to vary their posture throughout the task because the work station is too dense. Theres always been a need for a good housekeeping on the materials and equipments, as well as the need for training among the workers, and the management on the safety management.

CONCLUSIONS Work pieces in a welding industry can be hot, and this may not always be visually apparent. Improper personal protective equipment doesnt provide insulation, thus increasing the risk on the metal workers. Risk such as burns to the skin from the spark or light from arc welding; the dust (grind metals) and fumes (arc welding) that can be inhaled; improper working posture and repetition of the task in extended periods. Maintaining a work space free of flammability hazards is one of the best ways to reduce the risk of fire. Although, wearing of protective equipment does not allow any harmful penetration to the body, it has also a disadvantage. It shields the normal circulation of air in the body and reduces the bodys temperature which can result to heat stress. Accidents had not yet occurred in the workplace, but theres still a need for compliance for a safety management.

11 RECOMMENDATIONS Compliance to the safety management should not be overlooked. In order for the company to be productive and avoid subsequent consequences of accidents, the following are facilitated: y y y Always use a licensed electrician to wire machines Strictly implement the wearing of personal protective equipments that will provide insulation to the body. Workers with implanted medical devices pace makers and with any medical history should stay away from the welding equipment that utilizes high frequency radiation. Provide a first-aid kit and training. Consider housekeeping by separating the pieces of metals that had been cut, the equipments and tools. Works station must allow the workers to move or access comfortably by omitting the density of the workplace. The management must conduct a regular evaluation to the worker and work stations safety.

y y y y

12 BIBLIOGRAPHY Electronic Sources

Body protection. Retrieved from: http://www.hse.gov.uk/fod/infodocs/66825.pdf

Gilgenbach, Karen. (Apr 2011). 7 welding risks demand your attention. ISHN 45.4: 1,26,28.

Personal Protective Equipment. Retrieved from :http://www.deir.qld.gov.au/work place/subjects/ppe/index.htm

Safety shop The Definitive On-Line Safety Buyers Guide Rock Salt Supplier at www.safetyshop.com

13 Curriculum Vitae

Name: Agacita, Angelica Ocon Birthdate: January 1, 1991 Age: 20 Address: Block 6 Lot 4 Pereville Subdivision, Pagsabungan Mandaue City Email Address: angelicaagacita@yahoo.com Contact no: 09329160197

Education: 2007-2010 2010 Present University of San Carlos Talamban Campus University of San Jose Recoletos

Experience: Feature Writer Louisian Magazine (2003-2006) Filipino Editor Louisian Magazine (2006-2007) Physical Committee Collegiate Engineering Council USC TC (2008-2009) Sponsorship Committee Collegiate Engineering Council USC TC (2009-2010)

14 Appendix A COMPANY PROFILE JRJ TINSMITH WORK AND SERVICES Proprietor: Juan Jun Boquecosa Address: 13C T-Padilla Extension Cebu City, 6000 Philippines Contact Info: 416 8274 0919-2576615 (032) 581-3718 In service: 15 years since 1996

Services offered: y y y y y y y y y HVACs duct fabrication and insulation Steam and chilled pipe cladding insulation Revolving roof ventilation Life raft Dust collector Kitchen hood Water tank Bakery equipment fabrication Blower fabrication and installation

Appendix B We are a group of students from the University of San Jose-Recoletos of Industrial Department of College of Engineering and with due process we humbly ask your responses out from this set of questions. This is in lieu, with our final requirement of our course, Safety Management. Rest assured that your answers and the information gathered will remain confidential and shall be treated for academic purposes only.

Age: ______

No. of years or months of employment: _____

Gender: _________ Position: _____________________________ Please answer the questions to the best of your knowledge. Put a check mark on YES column if the following statements or practices are being applied in the workplace, and a checkmark on NO if otherwise. If, in any case, the statement or practice does not apply to the type of operations the company has, put a checkmark on N/A column.

QUESTIONS
1. Communication in Safety and Human Relations in the Organization 1.1. Communication in Safety 1.1.1. The management provides written communication (memos, guidelines, etc.) for workers who are dealing with complicated and technical problems. 1.1.2. Operators are briefed for instructions and other specifications before starting a new project or product. 1.1.3. Workers are able to express their concerns to the management and immediate actions are done, if necessary. 1.1.4. The management or officer-in-charge discusses the hazards of the job and how to avoid them. 1.1.5. An accessible bulletin board or information area is available for postings, updates and reminders in the workplace. 1.2. Human Relations 1.2.1. The management helps operators maintain job satisfaction by showing them how their work is a vital part of the product or project. 1.2.2. Workers are recognized and acknowledge for a job satisfactorily done. 1.2.3. The workers have a sense of team identity and maintain friendly atmosphere in the workplace. 1.2.4. The management shows respect for employees. 1.2.5. The management understands and is sensitive to the workers needs and concerns. 2. Employee Safety Training

YES NO

N/A

2.1. The management provides an orientation and training about: 2.1.1. General company rules and employee benefits (esp. medical and insurance). 2.1.2. Standard safety operating procedures, proper working conditions and safety precautions. 2.1.3. All hazards the workers are exposed to, according to the type of task engaged with. 2.1.4. Equipment or machine handling. 2.1.5. First Aid treatment procedures. 2.2. Handouts or other written materials are given to the employees. 2.3. A follow-up is made by the management or officer-in-charge after conducting an orientation or training. 2.4. A regular safety training is conducted regularly, together with an assessment of the performance of employees with regard to the previous training held. 3. Safety Inspection in the Workplace 3.1. Routine inspection (at least on a daily basis) done with strict compliance to the safety rules and procedures set by the company. 3.2. A formal safety inspection is conducted regularly with documentation. (Please indicate period: monthly, quarterly,) 3.3. Corrective actions are done on the problems covered during inspection. 4. Industrial Hygiene and Personal Protective Equipment 4.1. Industrial Hygiene 4.1.1. Proper ventilation is present in the workplace, (this should be enough to not contain the area with hazardous gases, fumes and dusts that are suspended in air) 4.1.2. Workplace has opens spaces (e.g. windows) that prevents noise isolation. 4.1.3. Production wastes are disposed and segregated properly. 4.1.4. Lay-out of work area is convenient for operations. 4.1.5. Workplace is cleaned and arranged, as much as possible right after performing a task (Clean As You Go) or at least after shift. 4.2. Personal Protective Equipment 4.2.1. Appropriate protective equipment of good quality is provided. (Please determine PPE according to the task performed.) a. goggles b. face shields c. Steel-toe Shoes or other designs that protects feet from sharp or falling objects d. over-all coat or wardrobe that enables worker to move freely e. gas masks f. earplugs or ear muffs g. gloves (according to the type of materials handled or used during operations)

4.2.2. PPEs are worn correctly. 4.2.3. PPEs are maintained and replaced when already non-functional. 4.2.3. The management shoulders maintenance and replacement of PPEs. 5. Machine and Equipment Guarding 5.1. Machine and equipment guarding 5.1.1. Machine safeguards are provided. 5.1.2. Safeguards are efficient. (able to prevent worker s hands, arms, and other body parts from making contact with machine s dangerous moving parts) 5.1.3. Safeguards are firmly secured and can be removed when need arises. 5.1.4. Worker is assigned to maintain machine guarding. 5.2. Mechanical Hazards 5.2.1. Point-of-operation safeguard is provided for the machine. 5.2.2. Machine guards are installed before the machine is turned on. 5.3. General Lay-out 5.3.1. Workplace is well-organized and free of possible hazards. 5.3.2. Precautions and signage are placed accordingly and are visible. 5.4. House-keeping 5.4.1. There is adequate space between machines. 5.4.2. Receptacles for wastes and debris are in convenient locations. 5.4.3. Supplies and tools are returned to their proper places. 5.4.4. The workplace practices 5S. (sweep, sort, sanitize, store, ) 6. Manual Material Handling and Storage 6.1. Lifting and Carrying 6.1.1. Materials are classified accordingly. 6.1.2. Materials are placed on containers with handles for a firm and easy grip. 6.1.3. Proper lifting or carrying of materials. (E.g. enough effort exertion, gradual lifting with no jerking, load kept close to the body, no twisting of body, etc.) 6.1.4. Appropriate hand gloves are worn for a particular material handled. 6.2. Storage 6.2.1. Materials (esp. chemicals) are labeled properly. 6.2.2. Materials that react with each other are stored separately. 6.2.3. Tools are stored properly with labels. 6.2.4. Storage is well ventilated and lighted. 6.2.5. Storing instructions are provided for a certain material or equipment 6.2.6. Storage is accessible (in convenient location and shelves are within reach). 7. Electrical and Fire Safety

7.1. Electrical safety 7.1.1. Workplace is clear of dangling wires. 7.1.2. Outlets are accessible to equipment needing electricity. 7.1.3. Proper electrical installations. (No octopus wiring, tangled wires, etc.) 7.1.4. Wirings on equipment cords are inspected before use. (No frays, cracks, or exposed wiring.) 7.1.5. Defective electrical equipment are tagged and removed immediately for repair or replacement. 7.2. Fire Safety 7.2.1. The management provides information on fire safety measures. 7.2.2. Combustible substances or materials are stored properly and are only present in the workplace when they are needed. 7.2.3. Fire exit routes are unobstructed. 7.2.4. Fire exits are visible and accessible. 7.2.5. People in the workplace are aware of the nearest fire exit in their area. 7.2.6. Fire drills are conducted. 7.2.7. Fire extinguishers are replaced annually. 7.2.8. Functional smoke detectors and sprinklers are installed in the workplace. 8. Accident Investigation and Documentation 8.1. Accident Investigation 8.1.1. All accidents and near misses are reported immediately to management. 8.1.2. Immediate medical attention is given to the injured worker. 8.1.3. Causes are determined and data are gathered in an appropriate time frame (as soon as possible). 8.1.4. Corrective actions are done after determining the cause of an accident to prevent recurrence. 8.2. Documentation 8.2.1. Accidents and near misses are well documented (includes photographs and interviews from the worker, witnesses and other people responsible). 8.2.2. Documents or reports are stored properly.

Thank you for your time and cooperation your responses are very valuable. May God bless you and more power!

8 Personal protective equipment

The following are made available in safetyshop.com Safetyshop.com only made access to DHL for shipping. Shipping rate can be access through www.DHL.com

The following are made available in Belmont hardware Cebu

Helmet Php 243.00 Eye shield Php 116.50

Php376.76

5.50

1217.95

17.78

Boots Cost (Belmont) Php 1,418.00 Helmet: 243.00 Glasses: 116.50 Gloves Php 27.00 Boots: Mask: 1,418.00 85.00 Expenses:

PPE Training

5668.50 7000__

Total: Php 12,668.50

Gloves: 27.00_____ Workers 3 * 1889.50 Mask Php 85.00