abc factory (unit -2) occupational health management report
TRANSCRIPT
ABC Factory (Unit -2) Occupational Health Management Report
A B C F a c t o r y
A l a i n C i t y
U n i t e d A r a b E m i r a t e s
+ 9 7 1 - 5 6 - 4 2 7 3 3 0 7
5 / 1 / 2 0 1 5
By: Student No.
Overall the Factory is well maintained.
Occupational Health & Safety Management
System is in place. Compliance against Abu
Dhabi Environmental Health & Safety
Management System Regulatory Framework is
observed. Management is found committed
towards zero tolerance against ill-health.
However, there is a good system in place
but still there is a reasonable potential of
improvement in occupational health
management. Some common health
hazards i.e., Entomopathogenic fungi,
Poor Air Quality, Display Screen Equipment,
Hazardous Substances, Noise, Stress,
Working in Heat, Dust, Bad, hygiene
condition and Smoke require urgent
attention.
1 CONFIDENTIAL
Contents
PRACTITIONER QUALIFICATION .................................................................... Error! Bookmark not defined.
EXECUTIVE SUMMARY ............................................................................................................................... 3
1) DESCRIPTION OF THE WORKPLACE AND ACTIVITIES ..................................................................... 4
2) IDENTIFICATION OF OCCUPATIONAL HEALTH HAZARD ................................................................ 5
2.1) RANGE OF OCCUPATIONAL HEALTH HAZARDS .................................................................................. 6
2.2) JUSTIFICATION OF SELECTION OF ONE HAZARD .............................................................................. 9
3) BACKGROUND RESEARCH .............................................................................................................. 10
4) ASSESSMENT OF RISK ..................................................................................................................... 11
4.1) METHODOLOGY: ......................................................................................................................................... 12
4.2) SELECTED ONE HEALTH HAZARD ......................................................................................................... 13
5) PROPOSED CONTROL MEASURES ................................................................................................. 17
5.1) ACTION PLAN .............................................................................................................................................. 19
6) Reference / Bibliography ................................................................................................................... 24
7) Appendices ......................................................................................................................................... 25
8) Abbreviations ..................................................................................................................................... 26
2 CONFIDENTIAL
PRACTITIONER QUALIFICATION
Disclaimer: This report is intended for educational purpose only. It cannot be disclosed, shared and/or
published for any other reasons.
3 CONFIDENTIAL
EXECUTIVE SUMMARY
ABC Factory is considered as industrial complex where it includes 6 productive units producing the following
types of fertilizers:
General types of products Specialties types of products Organochemicals fertilizers Chemical fertilizers Water saver " bentomix "
Liquid fertilizers Agri potting soil Agri pots New unit to deal with organic farming
biotechnology .
ABC FACTORY – Alain is keenly working for the betterment of their workforce. Overall, the ABC FACTORY
Factory is well maintained and compliance against AD EHSMS RF is observed. Management is found
committed towards zero tolerance against ill-health.
Few of good Observations are: ABC FACTORY has many national & international Certificates/awards
including but not limited to KIDPA (Khalifa international date palm award) distinguished product 2008, ISO
Certificate 9001/2008. Management office and production zones are, kept apart to avoid adverse health effects
of production to managerial staff. Health impact assessment is part of procurement policy. None of the
enforcement action against occupational health breaches, is noticed since inception of the factory. An effective
Emergency Management System is in place to deal with spillages, emissions and contaminations to least
affect the health of workforce. However, there is a good system in place but following Requires Urgent
Management Attention:
Biological Hazard (Entomopathogenic fungi)
Air Quality
Display Screen Equipment
Hazardous Substances
Noise
Stress
Working in Heat
Dust
Bad, hygiene condition
Smoke
Recommended additional controls:
Specific Training/Awareness about Entomopathogenic fungi
Keep production area workstations clean with antifungal substance.
Keep pantry area clean with antifungal substance.
Keep rest rooms clean with antifungal substance
Provide respirators instead of paper masks in high risk areas
Provide Hand washing facilities with antiseptic soap
Ventilate especially in production and storage areas
Display 7 steps of hand washing in conspicuous place
Ensure new gloves, new/washed aprons & clothing every day
Management needs to allocate reasonable resources (worth 56,500AED) to resolve high risk Entomopathogenic fungi concern on top priority to ensure zero workplace ill health, enhanced production and to avoid any enforcement actions.
4 CONFIDENTIAL
1) DESCRIPTION OF THE WORKPLACE AND ACTIVITIES
ABC Factoryis situated in Alain, an emirates of UAE. It was established in 1995 and started the
commercial production on 1997 as national company tending to recycle the animal manure (cow
poultry) & plant wastes in order to produce natural organic fertilizers & agricultural potting soil, free of
nematodes and other pathogens and environment friendly. Production capacity of the factory is 500
tons per day of heat treated organic fertilizers.
ABC FACTORY consists of 104 employees, 24 are Managerial and rest of 80 are general workers. ABC Factoryis considered as industrial complex where it includes 6 productive units producing the following types of fertilizers:
o General types of products o Specialties types of products o Organochemicals fertilizers o Chemical fertilizers o Water saver " bentomix " o Liquid fertilizers o Agri potting soil o Agri pots o New unit to deal with organic farming biotechnology
ABC Factoryis holding the below mentioned certificates & awards:
o KIDPA (Khalifa international date palm award) distinguished product 2008. o ISO Certificate 9001/2008 o Membership of the IFOAM (International Federation of Organic Agriculture Movement) o Membership of DAR (Deutcher Akkreditierug Rat) o Sheikh Khalifa Industry award for 2000/ 2001
Being one of the leading Bio-fertilizer companies in the Middle East, ABC Factory(ABC FACTORY) is
fully committed to the health & safety of its employees, visitors & contractors as well as Environment.
The objective is to achieve excellence in management of environment, health and safety by ensuring
compliance to ADEHSMS RF and any other applicable legal and other requirements. In addition to
ensuring compliance to the legal and other requirements, top management is committed to:
5 CONFIDENTIAL
2) IDENTIFICATION OF OCCUPATIONAL HEALTH HAZARD
Quantitative Risk rating based on probability and severity will be used to priorities the significance of
the hazards to facilitate the decision-making in focusing the most significant hazards.
6 CONFIDENTIAL
2.1) RANGE OF OCCUPATIONAL HEALTH HAZARDS
S/
N HAZARD RISK ACTIVITY/ TASK
RISK RATING
Proba
bility
(P)
Severi
ty (S)
Rating
(PxS)
1
Biological
Hazard
(Entomopatho
genic fungi)
May result in allergic reactions if
inhaled. Few contaminants like
Aspergillus spp are harmful which
may cause Aspergillosis.
Moreover skin allergies, deep
tissues infections, digestive
disorders, food contamination
and respiratory diseases are
pretty common.
Extensive use of
organics in
production of bio
fertilizers, leads to
high potential of
Entomopathogenic
fungi exposure.
4 3 12
2
Poor Air
Quality
Poor or unhygienic centralized air
supply may lead to related
illnesses.
Substantial usage of
Biological material in
production may
contaminate the air
quality to managerial
and production staff,
which may give rise
to related illnesses.
2
2
4
3 Display Screen
Equipment
Headaches, sore eyes, skin
allergies may occur from screen
glare or if lighting is poor.
DSEs without any
protectors, without
consecutive breaks
are being used in
management office
which may lead to
headaches , sore
eyes and skin
allergies
2 3 6
7 CONFIDENTIAL
4
Hazardous
Substances to
health
Cleansing Hazardous
substances may lead to skin
allergies, burns, eyes soaring or
ill health, if inhaled.
Exposure or contact
with Washroom,
kitchen, glass
cleaning chemicals
while routine
cleaning.
3 3 9
5 Noise
Staff may be exposed to high
levels of noise, inducing hearing
impairment.
Noise from
production machines,
conveyor belts,
heavy vehicles may
result in stress,
tinnitus and hearing
impairment
2 3 6
6 Stress Work related stress may lead to
physical or mental illness
High workload
without consecutive
breaks and least
appreciation can
result in
psychological
disorders
3
2
6
7 Working in
Heat
Working in heat may lead to heat
exhaustion, heat stress, heat
stroke and related illness.
Labor working on
loading/unloading
bay, open storage
area is exposed to
extreme heat,
especially in summer
and peak hours 12
noon to 3pm. Heat
exhaustion, heat
stress and heat
stroke.
3 4 12
8 Dust
Excessive exposure to dust may
lead to cough, eyes irritation,
asthma and other serious health
concerns
Production areas,
storage area,
vehicles
maneuvering tracks
are not concreted or
tiled. Wind blows
excessive dust
throughout the
3 3 9
8 CONFIDENTIAL
factory, which may
lead to cough, eyes
irritations and
asthma. It may leads
to silicosis.
9
Bad, hygiene condition
Food and drinks are taken to production line, which is unhygienic and may contaminate food with biological microorganism.
Poisoning, Vomiting, diarrhea are some of possible adverse health effects on the workers.
2 3 6
10 Smoke If trapped, staff could suffer fatal
injuries from smoke inhalation
Storage area does
not have clear exit
signage and poor
lighting may hinder
evacuation, which
can lead to fatal ill
health and injuries
from smoke
inhalation.
2 4 8
9 CONFIDENTIAL
2.2) JUSTIFICATION OF SELECTION OF ONE HAZARD
Entomopathogenic fungi (Biological Hazard), is being selected because it's very specific hazard
with bio-fertilizers industries unlike other health hazard which are almost common in every industry i.e.,
stress and smoke. Moreover, I believe, biological hazard are one of the leading reason for causing ill-
health at workplace. Selection of Entomopathogenic fungi (Biological Hazard) also shows my
intensive and detail examination of the industry as its not pretty common and known hazard to
everyone. Most of the labor was found unaware of this hazard and its consequences. None of the
specific training was ever organized by the company in this regard. That's why it was vital to select this
biological hazard for detail risk assessment.
10 CONFIDENTIAL
3) BACKGROUND RESEARCH
Entomopathogenic fungi vary considerably in their mode of action and virulence. Successful infection
depends primarily on the adherence and penetration ability of a fungus to the host integuments. A
variety of extracellular enzymes is produced during the degradation of insect integument. The attempts
to control insects have changed over time from chemicals to natural control methods. This is why the
development of natural methods of insect control or biopesticides, is preferred. By the use of fungal
entomopathogens, insect pests can be controlled. There is no doubt that insects have been used for
many years, but their effective use in the field remains elusive. However, their additional role in nature
has also been discovered. Comparison of entomopathogens with conventional chemical pesticides
depends on their efficiency and cost. In addition to efficiency, there are advantages in using microbial
control agents, such as human safety and other non-target organisms; pesticide residues are
minimized in food and biodiversity increased in managed ecosystems.
(reference: http://www.doiserbia.nb.rs/img/doi/0354-4664/2012/0354-46641201021S.pdf)
3.1) HEALTH EFFECTS:
Following are some common health effects if exposed to Entomopathogenic fungi;
Deep tissues infection
Skin Allergies
Respiratory infection (if inhaled)
Eyes infections
Food contamination
Digestives disorder
3.2) LEGAL REQUIREMENTS:
In relation to occupational health, following legal requirements are imposed by UAE government.
EHSMS legislation (Executive Council Decree no 42 2009)
Abu Dhabi EHSMS regulatory framework Version 2.0
Federal Law no. 8 of 1980 – Labor Law and its amendments
Federal Law no. 24 of 1999 – protection and development of the environment
EAD’s Technical Guidance documents and standards
EAD permit conditions issued to ABC FACTORY
11 CONFIDENTIAL
4) ASSESSMENT OF RISK
The procedure of identifying potential hazards in combination with its consequences, which an
organization may face and analyzing controls if exposure occurs. Following five steps are taken into
account while assessing risk at workplace;
Identify the hazards (Risk Factor)
Identify who might be harmed and how
Evaluate the risks and existing precautions
Record your significant findings and implement them
Monitor &Review your assessment and update if necessary
12 CONFIDENTIAL
4.1) METHODOLOGY:
ABC FACTORY health management system is critically examined against AD EHSMS RF 2.0
requirements. To identify hazards and to assess risk, recommended 5x5 Risk matrix, is being
used to quantify associated risk.
Moreover, for sufficient amount of information, interviews with personnel are conducted to determine
their knowledge about Health management system, about their roles and responsibilities and their
awareness about ill-health incident reporting. Site inspection with critical examination of
documentation for last 1 year is performed. Site inspection and audit was supported by check list to
ensure consistency and accuracy of information.
13 CONFIDENTIAL
4.2) SELECTED ONE HEALTH HAZARD
In view of above Identified Health hazards, following high-risk, biological hazard is selected for the
detail risk assessment.
WORKPLACE / ACTIVITY /
EQUIPMENT BEING
ASSESSED:
Entomopathogenic fungi (Biological
Hazard)
Raw Material Insertion, Production,
Packing, Logistics
REVIEW
TIMESCAL
E:
Annually
PERSONS AT RISK-
AFFECTED BY ACTIVITY:
Employees (especially Production &
Packing), Logistic Contractors NUMBER 1 – 80
OTHER VULNERABLE
PERSONS AFFECTED BY
ACTIVITY:
End Users NUMBER Unlimited
POTENTIAL HAZARDS Assessment of Risk
RE
F.
Low Med High
1 Deep tissues infection √
2 Skin Allergies √
3 Respiratory infection (if inhaled) √
4 Eyes infections √
5 Food contamination √
6 Digestives disorder √
14 CONFIDENTIAL
EXISTING CONTROL MEASURES
Face Mask
Safety Gloves
Safety Aprons
Restricted visitors access
INITIAL ASSESSMENT OF RISK
(QUANTITATIVE)
LIKELIHOO
D 4 SEVERITY 3 RISK 12
INITIAL ASSESSMENT OF RISK
(QUALITATIVE) LOW MEDIUM
HIGH/E
XTREME √
15 CONFIDENTIAL
ADDITIONAL CONTROL MEASURES RESPONSIBLE PERSON COMPLETION
DATE
Specific Training/Awareness about Entomopathogenic fungi
Talent Management
Manager/Site
Supervisor
November 1, 2016 (1 Month)
Keep production area workstations clean with antifungal substance.
Procurement/Manager
Housekeeping/Product
ion supervisor
October 2, 2016 (Every Shift/Day)
Keep pantry area clean with antifungal substance. Procurement/Manager
housekeeping/Supervi
sor FNSD
October 2, 2016 (Every Shift/Day)
Keep rest rooms clean with antifungal substance Procurement/Manager
housekeeping
October 2, 2016 (Every Shift/Day)
Provide respirators instead of paper masks in high risk areas
Procurement/EHS
MR/Line
supervisor/Safety
officer
October 15, 2016 (2 weeks)
Provide Hand washing facilities with antiseptic soap Manager
Housekeeping/
Procurement
October 8, 2016 (1 week)
Ventilate especially in production and storage areas Site
Manager/Engineering
November 1, 2016 (1 Month)
Display 7 steps of hand washing in conspicuous place Admin Manager October 8, 2016 (1 week)
Ensure new gloves, new/washed aprons & clothing
every day
Admin Manager/Site
supervisor
October 2, 2016 (Every Shift/Day)
RESIDUAL RISK (QUANTITATIVE) LIKELIHOO
D 2 SEVERITY 2 RISK 4
RESIDUAL RISK (QUALITATIVE) LOW MEDIUM √ HIGH
Risk Assessment Circulation list (tick box)
Employees √ Management √ Contractors √
Other – Specify:
Signature of person primarily accountable / Date
16 CONFIDENTIAL
Assessor: S.T.K Signature:
17 CONFIDENTIAL
5) PROPOSED CONTROL MEASURES
In consistency to Section 2: Health Hazards and Section 3: Risk assessment, following realistic and
practical recommendations are classified and prioritized.
Priority 1: (Biological Hazard - Entomopathogenic fungi)
Heading towards hazards identification section 2 – Health hazards, top priority is Biological Hazard - Entomopathogenic fungi that may result in allergic reactions if inhaled. Few contaminants like Aspergillus spp are harmful which may cause Aspergillosis. Moreover, skin allergies, deep tissues infections, digestive disorders, food contamination and reparatory diseases are common. Extensive use of biological in production of bio fertilizers, leads to high potential of Entomopathogenic fungi exposure so should be deal as priority-1 among all other health hazards in bio-fertilizers factory. Recommended controls i.e., antifungal cleansing of workstations, pantries and rest rooms, provision of ventilation and additional PPEs, do require reasonable cost and other resources but still recommendation is pretty practicable and justified.
Priority 2: (Hazardous Substances)
Second highest priority in view of section 2 – Health hazards is “Hazardous Substances” used for cleansing. Exposure or contact with Washroom, kitchen, glass cleansing chemicals may lead to skin allergies, burns, eyes soaring or vomiting and other chorionic disease if inhaled. Procurement of less toxic chemicals, provision of masks and gloves, job specific training, MSDS and safety signage display will require some budget but insignificant. This cost can be justified, as it is just a tip of iceberg. Continuous exposure may lead to ill-health including acute and chronic disease which may go up-to 28 times of current cost.
Priority 3: (Working in Heat)
Excessive exposure to working in heat may lead to heat exhaustion, heat stress, heat stroke and related illness. Labor working on loading/unloading bay, open storage area is exposed to extreme heat, especially in summer and peak hours 12 noon to 3pm. Heat exhaustion, heat stress and heat stroke. Administrative controls i.e., limiting working hours, rotation, specific training and orientations, provision of shelter, cold water, hard hats and goggles will require insignificant cost and this cost is very much justifiable if cost of consequences is calculated. This comes in 3rd priority in view of section 2 – Health hazards.
Priority 4: (Dust)
Production area, storage area, vehicles maneuvering tracks are not concreted or tiled. Wind blows excessive dust throughout the factory, which may lead to cough, eyes irritations and asthma. It may leads to silicosis. Excessive exposure to dust may lead to cough, eyes irritation, asthma and other serious health concerns. Engineering Controls like concreting floors, constructing solid vehicle/pedestrians walkways will require significant budget and time but it is again justifiable by looking into indirect cost of relevant ill health and production delay etc.
18 CONFIDENTIAL
Note: Recommendations are prioritized according to their significance and risk classifications instead of
resources implication. We may reorder the priorities in reverse order if ABC FACTORY is more concern about
resources implication.
19 CONFIDENTIAL
5.1) ACTION PLAN
Recommendation Actions cost time scale
Responsibility Review
To control exposure to Biological Hazard - Entomopathogenic fungi Specific Training/Awareness about Entomopathogenic fungi Keep production area workstations clean with antifungal substance. Keep pantry area clean with antifungal substance. Keep rest rooms clean with antifungal substance Provide respirators instead of paper masks in high-risk areas – Raw material storage area etc.
Talent
management
needs to ensure
specific training for
all the staff through
external approved
trainer
Procurement to arrange antifungal substance for cleaning and housekeeping to ensure routine cleansing Procurement to arrange antifungal substance for cleaning and housekeeping to ensure routine cleansing Procurement to arrange antifungal substance for cleaning and housekeeping to ensure routine cleansing Procurement to arrange BS standard respirators 5 Pcs
Cost of training for all staff will be AED 20,000 with same cost of refresher every 3 years Cost of substance for a month approximately AED 500 Cost of substance for a month approximately AED 500 Cost of substance for a month approximately AED 500 Cost of 5 respirators approximately AED 5,000
3 Months Ongoing (Everyday) Ongoing (Everyday) Ongoing (Everyday)
Talent Management Manager/Site Supervisor Procurement/Manager Housekeeping/Production supervisor Manager housekeeping/Supervisor FNSD Manager housekeeping Procurement/EHS MR/Line supervisor/Safety officer
3 Years 1 Year 1 year 1 year 1 year
20 CONFIDENTIAL
Provide Hand washing facilities with antiseptic soap Ventilate especially production and storage areas Display 7 steps of hand washing in conspicuous place
and safety officer to ensure compliance in high-risk zones. Housekeeping to ensure provision of antiseptic soaps, tissues and dryers. Ventilate through engineering controls (LEV) to least the accumulation of biological hazards and to purify the air Print and display hand washing techniques especially in rest rooms and pantries etc.
Doesn’t require additional cost as its readily available in par level Engineering control may require up-to AED 30,000 Doesn’t require additional cost
2 weeks 1 week 1 Month 1 week
Manager Housekeeping Site Manager/Engineering/Safety officer Admin Manager
1 year 6 months 1 year
To avoid Hazardous Substances exposure Procurement of less toxic chemicals
HSE officer to recommend less hazardous chemicals for cleaning to procurement
Doesn’t require additional cost
2 weeks
HSE officer/Procurement
1 year
21 CONFIDENTIAL
Provision of masks and gloves to housekeeping staff. Job specific Training Display MSDS and Chemical safety signage Safe Chemical Storage
Admin to provide reasonable stock of disposable masks and gloves to housekeeping from existing par-level. Arrange Hazardous Chemical training through certified and approved third party trainer. Display Material safety data sheets and chemicals handling signs which are inserted in chemical boxes Store chemicals in designated but separated cabinet and display “Chemical stored” signage on it
Doesn’t require additional cost as its already part of par-level Does require budget for external training of approximately AED 4,000 for 10 personnel. Doesn’t require additional cost to procure as they are essential part of chemicals within chemical boxes Doesn’t require additional cost
1 Week 3 Months 1 week 1 week
Manager Admin/Manager housekeeping Talent Management Manager/Site Supervisor Safety office/housekeeping supervisor Safety office/housekeeping supervisor
1 Year 3 years 1 year 1 year
To stay safe while Working in Heat Limiting working hours and job rotation Provision of welfare facilities (Shelter, cold water etc)
Keep rotating staff to limit heat exposure and avoid working in peak hours 12-3pm. Ensure clean and cold water provision to avoid dehydration and
Doesn’t require
additional cost
Doesn’t require additional budget
1 week 1 Day
Admin Manager/Site supervisor/Safety officer Admin Manager/Site supervisor/Safety officer
3 Months 6 months
22 CONFIDENTIAL
Health Surveillance
shelter to intensity of the heat Run health surveillance program at least once a year with medical professional support to diagnose any possible heat exposure and its adverse effects
Requires reasonable budget for diagnostics and physical checkup. It can be approximately 30,000 AED per year.
EHS-MR/ Admin Manager
1 year
To avoid Dust inhalation and its consequences Concreting floors& constructing solid Pedestrians walkways Wetting ground/walkways Provision of BS standard Dust mask& goggles
Hire external engineering company for concreting floors and constructing walkways. Keep wetting ground and walkways twice a day at least to lessen the dust, if concreting cost is out of budget but it is just a temporary solution as it will give rise to slips and fall as well. Procurement of PPEs for all the staff personnel as per BS standards
Significant cost of AED 40,000 – 50,000 for concreting will incur but this is the only permanent solution for the Dust as other controls will be cheaper but temporary Doesn’t require additional cost Cost of PPEs for will be approximately AED 3,000
6 Months 1 Day 1 month
EHS-MR, Site Manage, Engineering, Site supervisor/ Supervisor housekeeping Manager procurement, line supervisor/Safety officer / EHS-MR
5 Years 1 Year 1 year
23 CONFIDENTIAL
24 CONFIDENTIAL
6) REFERENCE / BIBLIOGRAPHY
BSC CONTENT
BSC IDIP UNIT-2 GUIDANCE NOVEMBER 2015
OSHAD UAE
INDUSTRIAL SECTOR REGULATIONS
ABC FACTORY FACTORY INTERNAL DOCUMENTS
ABC FACTORY ISO Documents
ABC FACTORY WEBSITE
WIKIPEDIA
HTTP://WWW.DOISERBIA.NB.RS/IMG/DOI/0354-4664/2012/0354-46641201021S.PDF
25 CONFIDENTIAL
7) APPENDICES
LEGISLATIONS / REGULATIONS BREACHES (UAE)
EHSMS legislation (Executive Council Decree no 42 2009)
Abu Dhabi EHSMS regulatory framework Version 2.0
Federal Law no. 8 of 1980 – Labor Law and its amendments
Federal Law no. 24 of 1999 – protection and development of the environment
EAD’s Technical Guidance documents and standards
EAD permit conditions issued to ABC FACTORY
26 CONFIDENTIAL
8) ABBREVIATIONS
o HSE : Health, Safety and Environment
o EHS : Environment, Health and Safety
o ADEHSMS : Abu Dhabi Environmental Health & Safety Management System
o OSHAD : Occupational Safety & Health Abu Dhabi
o EHS-MR : Environment, Health & Safety Management Representative
For detailed terms and definitions, Abu Dhabi Regulation Framework – Glossary of Terms Ver. 2.0 2012
----------------------------------- END OF REPORT --------------------------------------