Bara Chemical Co., Ltd.

GPS Workshop, ThailandMay 26,2015

Risk Assessment and Management of Workplace

[Session 5]

Establishment : 1973 March Registered Capital : 60 MBaht Shareholders : Sumitomo Chemical 55%

Bara Windsor 45% Factory Area : 28,000㎡ No. of Employees : 140 persons

(Japanese 4 persons) Address : Bangpoo, Samutprakarn,

Thailand

Bara Chemical Co., Ltd.

AUTOMOBILE and TIRE & RUBBER MANAGEMENT SYSTEM

– Rubber Adhesive for Automobile Tire– Acrylic Emulsion for Car Sheet– Primary Paint for Car Bumper

– ISO 9001– ISO 14001– OHSAS 18001

Product & Management System Overview

TEXTILE

PAPER

ELECTRONIC

OTHER

– Textile Finishing Resins

– Printability Improving Resin– Wet Strengthen Resin

– Epoxy compound– Epoxy Resin for LED lamp

– Instant Glue– Corrosion InhibitorPLASTIC ADDITIVE

– Plastic Additives

What is Bara Chemical ?

Consolidated Subsidiary of Energy and Specialty Chemicals Sector,

Sumitomo Chemical (SCC).

Production Site of fine Chemical Products of SCC and SCC group.

Regional Technical Service Base of Dyestuff Business of

Sumitomo Chemical in South East Asian market.

Bara Chemical Co., Ltd.“To maintain the good hygienic of

the production staffs”

Chemical Risk Assessment

(Health Hazard Prevention)

Introduction

Since September 2012 the Bara Chemical has been certified OHSAS 18001 (Occupational Health and Safety Management System), risk management was based on general prevention not specific for hazardous prevention.JISHA’s Chemical Risk Assessment Method for Health Hazard Prevention which was introduced to Thailand by HIDA (The Overseas Human Resources and Industry Development Association) and JCIA (Japan Chemical Industry Association) started to implement in Bara Chemical process.

What’s JISHA's Chemicals RA Program Guide (Health Hazard Prevention)

The Japan Industrial Safety and Health Association (JISHA) issued a

manual entitled JISHA's Chemical RA Program Guide (Health Hazard

Prevention) for the investigate of the hazardous nature of chemical substances).

Steps 1 to 4, 9, and 10 of this manual are similar to those specified for standard

risk assessment.

Steps 5 to 8 are specific to the risk assessment of chemical substances, and

contain consideration of hazard evaluation and measures for the prevention of

exposure to hazardous chemical substances.

JISHA's Chemicals RA Program Guide ; Risk Assessment Flow Chart

Step 1: Assign the risk assessor

Step 2: Divide manufacturing/handling processes/workplaces into units to implement RA

Step 3: Make an inventory of chemicals used. Obtain info. on workplaces/processes

Step 4: Identify workers engaged in the RA target workplaces

Step 5: Gather and evaluate the hazard

data, etc. (Hazard assessment)

RA goals, sites, and scope

Identify chemicals manufactured/handled

Identify target workers

Step 6: Gather and evaluate the exposure

data. (Exposure assessment)

- Identify the hazard data (GHS classifications, OELs: Occupational Exposure Limits, BEI, etc.)- Identify the hazard level (HL)

Step 7: Risk characterization

Step 8: Develop the Risk control measures

to prevent/reduce exposure

Identify the exposure level

Identify the

risk level (RL)

Step 9: Identify RMMs*, implement them, and document the outcomes

Step 10: Reassessment

Risk-level-relevant risk control measures

*) RMMs: Risk Management Measures

PDCA cycle (plan-do-check-act cycle)

Risk Level (RL) V = Intolerable riskRisk Level (RL) IV = High riskRisk Level (RL) III = Medium riskRisk Level (RL) II = Allowable riskRisk Level (RL) I = Minor riskRisk Level (RL) S = Risk to eyes and skin

Step 5: Gather and evaluate the hazard data, etc. (Hazard assessment)

Hazard assessment level (HL) must be considered the impact of carcinogenicity

that classified in category 1A, 1B, 2

Step 6 - 7: Exposure Assessment and Risk Characterization

Yes Yes Yes No

(Table1)Risk characterization table for EL1, EL2, EL3 (Table2)Risk characterization table for EL4

HL from STEP 5

STEP

6ST

EP 7Measureddata 

available?

Option 1 Av : Working

Environment  data.

Option 2Av : Personalsampler  data.

Option 3Av : Biological 

monitoring data.

Option 4No data Available.

Working  Environmentconcentration  Level  (WL)

&Working Time Level  (FL) 

Exposure Level  : EL 4

Estimated Working  Environment

concentration  Level  (EWL)&

Working  Time Level  (FL) 

ELHL

V V IV III II

V IV III III II

IV IV III II II

IV III III II I

IV III III II I

4 3 2 1

5

4

3

2

1

5 ELHL

V V IV IV IIIV IV IV III IIIIV IV III III IIIV III III II IIIV III III II I

21

3 2 1

543

5 4

Exposure Level  : EL 1 Exposure Level  : EL 2 Exposure Level  : EL 3

Risk Level (RL) V = Intolerable risk

Risk Level (RL) IV = High risk

Risk Level (RL) III = Medium risk

Risk Level (RL) II = Allowable risk

Risk Level (RL) I = Minor risk

Risk Level (RL) S = Risk to eyes and skin

Bara Chemical Step wise

Step 1 – 3 Divide the manufacturing process to implement Risk Assessment Step 4 Describe the chemical used, chemical released and Priority by GHS

classification consider on health hazard firstStep 5 Gather and evaluate the hazard data (Hazard Assessment)Step 6 Identify the exposure level (Exposure Assessment)Step 7 Risk CharacterizationStep 8 Develop the Risk control measures to prevent/reduce exposureStep 9 Identify risk management measure, Implementation and document

the outcomeStep 10 Reassessment

Source of information;Speaker Mr. Jun Yamaguchi, HIDA Expert (The 1st Seminar on Chemical Risk Assessment Method)

Manufacturing Process for Chemical Risk Assessment

Hazard DataFormaldehyde (ACGIH) Threshold Limit Value (TLV) (2007) = 0.37 mg/m3

Manufacturing process of Melamine Resin

- Material - a- Material - b- Material - c- Material - d- Material - e

Reflux &

Vacuum condensation

Cycle time of 1 Batch size

Working time = 12 hrs/shift/operator

Break = 3 hrs/shift/operator

Manufacturing Process for Chemical Risk Assessment

FF

FF = 0.057 mg/m3

< 0.001 mg/m3

Melamine Resin: Carcinogenicity 3Formaldehyde vapor: Carcinogenicity 1A

Inventory of chemical used and prioritization by GHS

Hazard Assessment (HL)

Chemical GHS HLComponent Classification (Hazard Level)

Melamine ResinCarcinogenicity

1A 5

Formaldehyde vapor

Carcinogenicity 1A 5

Refer to JISHA’s Guide: Table 1-1 Hazard Level

Exposure Assessment and Risk Characterization

Wet scrubber for dust & vapor collector and treatment unit.

Workplace control measures

Facilities to control formaldehyde vapor, Mixing tank

Closed system for vapor control to collect Formaldehyde vapor to scrubber

Facilities to control formaldehyde vapor, Vacuum pump

Workplace control measures

Although, even if the control system and the measuring chemicals in the atmosphere are not over than standard, the PPE is still necessary to minimize the effect to the operator.

Workplace control measures

1. Educate the operators about Health Hazards of formaldehyde exposure.

2. Provide an appropriate personal protective equipment (PPE). Ensure that the staffs always use PPE such as impervious clothing, gloves, aprons, and chemical splash goggles to prevent skin and eye contact with formaldehyde.

3. Conduct annual medical check up and report abnormalities immediately

Standard, Training and Health check investigation