Creating Safer Working Environment at Technical

Department and Spreading Section of Harvik Rubber

Industries S.B.
Buvearasan Muniandy, NS8303
780911-02-5875

Alert today, alive tomorrow!

Introduction
Harvik Rubber Industries S.B. started
operation 1973. Making hand crafted rubber
safety & non safety boots
An ISO 9001:2008 & ISO 14001:2004
certified company
Current workforce 450 people
Major processes/ production areas Mixing,
Machine Hall, Moulding, Cutting, Preparation
& Assembly
Technical Department as servicing party
2

Objectives
To identify safety and health hazards related
to workplace activities
To describe techniques to be used in
identifying safety and health hazards at
workplace
To assess hazard and using risk matrix
To prepare risk ranking to identify critical
hazards
To indentify and propose control measures
for critical hazards either by eliminating,
substituting, isolating, applying engineering3

Objectives
To review the effectiveness of risk
assessment phase and implementation of
proposed control measures
To increase awareness and direct
involvement of employees and top
management in Safety and Health
Management System
To encourage effective management of
workplace safety and health hazards
To create a safer and healthier workplace for
all employees
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Selected Processes
Processes that have been chosen for this
study
Testing processes by Technical
Department
Spreading process by Machine Hall
Section

Technical
Department
Testing Process
(Compound mixing)

Technical
Department

Machine Hall
Spreading Process
5

Overall Process Flow Chart

A

Epitome of
Rubber Boot
Manufacturing
Process

Selected Processes

Flow chart of
Compound Mixing
Process

Flow chart of
Sample Testing
Process

Flow
chart of
Spreadin

Methodology
Identification of HAZARDS (health hazards,
safety hazards & environmental hazards)
Three main methods used in this study
Observation
Document review
Interview

Methodology
Observation
Compound Mixing Process
Chemical weighing, mixing & sheeting out

Sample Testing Process

Performing the test using machine &
equipment

Spreading Process
Execution of process and specific area in the
process where solvent vapour get released

Methodology
Document Review
Compound Mixing Process
Data on previous incidents, CHRA report,
Safety & Health highlights in work instruction
and MSDS

Sample Testing Process

Test procedure and CHRA report

Spreading Process
Literature on textile rubber coating, CHRA
report and MSDS
10

Methodology
Interview
Compound Mixing Process
Lab technician handling of raw chemical,
awareness on PPE and chemical exposure

Sample Testing Process

Potential hazard during test performance and
comfortability during testing,

Spreading Process
Production Operator - Transfer of material,
smell of gasoline, awareness on PPE and
chemical exposure
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Risk Assessment
Risk
Matrix
Severity
Likelihood

Fatality
(4)

Major injury Minor injury

(3)
(2)

Neg. injury
(1)

Very likely
(4)

High
(16)

High
(12)

High
(8)

Medium
(4)

Likely
(3)

High
(12)

High
(9)

Medium
(6)

Medium
(3)

Unlikely
(2)

High
(8)

Medium
(6)

Medium
(4)

Low
(2)

Very unlikely
(1)

Medium
(4)

Medium
(3)

Low
(2)

Low
(1)

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Risk Assessment
Risk Score
Index

Process

Safety hazards
1
Compound
Mixing
2
Compound
Mixing
3
Sample
Testing
4
Sample
Testing
5
Sample
Testing
6

Hazard

Impact

Tacky rubber compound

Severity Likelihood

Rel.
Risk

Risk
Level

Hand gets draw-in

into mill
Oily surface of rubber
Oil spillage results in
processing oil bottle
slip and fall
Sharp edge of cutting dies Hand cut

12

High

Low

Low

Accidental drop of
Hand injury
moulds upper platen
Slip-off of sample fixed on Slipped-off sample
impact tester
can fly and hit people
at surrounding
High static charge build- Fire emergency
up at spreading machine

Medium

Medium

High

Skin irritation and

allergy
Toxicity

Medium

Medium

Toxicity

High

Spreading
Process
Health hazards
1
Compound
Skin contact with rubber
Mixing
chemicals
2
Sample testing Inhalation of chemical
vapour
3
Spreading
Inhalation of solvent
process
vapour

13

Risk Assessment
Inde
x

Hazard

Risk Action
Severi Likeliho
Table
ty
od

Safety hazards
1
Tacky rubber compound
2
High static charge buildup at spreading machine
3
Accidental drop of
moulds upper platen
4
Slip-off of sample fixed on
impact tester
5
Oily surface of rubber
processing oil bottle
6
Sharp edge of cutting
dies
Health hazards
1
Inhalation of solvent
vapour
2
Inhalation of chemical

Relati Risk Priori

ve
Level
ty
Risk

3
4

4
2

12
8

High
High

1
2

Mediu
m
Mediu
m
Low

Low

High

3
3

Mediu

4
5

14

Critical Hazard
Safety Hazard
Tacky Rubber Compound during compound
mixing
Relative risk score of 12 and highest among
identified safety hazards
Compound mixing on daily basis - high
frequency (4) for Likelihood
Potential to loss their fingers major injury
(permanent disability , 3) for severity
Score of 12 - High Risk based on Risk
Ranking Table

15

Critical Hazard
Health Hazard
Inhalation of solvent vapour by Spreading
Machine operators
Score of 9 - highest under risk tabulation for
health hazards
Operating the machine on daily basis with
intermittent stops - rating of 3 under
Likelihood
Inhaling solvent vapour would be toxicity
and related diseases - Severity rating of 3
Score of 9 - High Risk based on Risk Ranking
16
Table

Impact of Critical Hazards

Critical Safety Hazard

Critical Health Hazard

Cease of operation

Get charged if proven to be guilty in

neglecting workers safety

Lower productivity due to

absenteeism/ medical leave

Tarnishing of organization reputation

Compensation for affected worker

Lose of income due to permanent

disability

Increase in medical
workplace illnesses

Short term business loss temporary

cease of operation

Company may face lawsuit if any death

of an employee proven because of work
related illness.

Long term business loss customers

moved to alternative suppliers

Potential of lower product quality

Difficulty in getting manpower

Loss of skills

Monetary loss - high compensation for

workers

Loss of trust employees on employer

Higher rate of medical leave

higher

expenses

17

Risk Control Measures

Critical Safety Hazard

Critical Health Hazard

Engineering control guarding for 2 roll

mill

Substitution solvent based material

replaced with water based material

Administrative control training, safe

work practices, detailed work instruction
and control of trained personnel

Isolation - Isolation of
Process from other areas

Use of PPE plastic/ rubber glove

topped with cotton glove

Engineering control - better exhaust

system and process automation

Administrative control training, safe

work practices, detailed work instruction
and rotation of workers

Use of PPE Respirator with solvent

absorbing cartridge and use of goggles

Spreading

18

Review Programmes

Monthly safety audit

Scheduled inspection
Feedback collection from floor members
Review on accident report level
Regular Safety Committee Meeting

19

Benefits of Recommendations

Minimize accident rate at workplace

Create a better repo among industries
Safer workplace motivate employees
Increased level of morale among workers
Dependable and safe workplace for
employees
Reduced budget on medical expenses
Mutual benefit between employees and
employer caring employer
20

Thank You!
Q &A

21