UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UNIVERSITI TEKNIKAL MALAYSIA MELAKA A STUDY OF SAFETY AND HEALTH AWARENESS AND NOISE ASSESSMENT AT STAMPING DIE COMPANY This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering (Manufacturing Management) (Hons.) by SITI NUR ADIBAH BINTI ITHNIN B051010249 890515-09-5190 FACULTY OF MANUFACTURING ENGINEERING 2013

UNIVERSITI TEKNIKAL MALAYSIA MELAKA BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA TAJUK: A Study of Safety and Health Awareness and Noise Assessment at Stamping Die Company SESI PENGAJIAN: 2012/2013 Semester 2 Saya SITI NUR ADIBAH BINTI ITHNIN mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( ) SULIT TERHAD TIDAK TERHAD (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysiasebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972) (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) Disahkan oleh: Alamat Tetap: 1692, Lorong Kempas 7/1, Taman Kempas, Sungai Petani,Kedah Cop Rasmi: Tarikh: Tarikh: ** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

APPROVAL This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a partial fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering (Manufacturing Management) (Hons.).The members of the supervisory committee are as follow: (Principal Supervisor) (Co-Supervisor)

DECLARATION I hereby, declared this report entitled A Study of Safety and Health Awareness and Noise Assessment at Stamping Die Company is the results of my own research except as cited in references. Signature :. Author s Name : Siti Nur Adibah Binti Ithnin Date : 3 cm

ABSTRAK Laporan ini disediakan untuk menerangkan kajian kesedaran keselamatan dan kesihatan di kalangan pekerja dan penilaian bunyi di syarikat acuan dan alat tekan. Kajian ini meliputi Akta Keselamatan & Kesihatan Pekerjaan (OSHA), OSHA 1994, bahaya, pendedahan bunyi bising dan pencegahan bunyi di Miyazu Malaysia Sdn Bhd (MMSB). Kaji selidik dijalankan mengenai tahap kesedaran pekerja kepada Kesihatan dan Keselamatan di persekitaran tempat kerja.kajian ini juga akan mengkaji tentang tahap bunyi yang dihasilkan mesin merujuk kepada piawai OSHA. Data yang telah diperolehi daripada beberapa kaedah termasuk pemerhatian, temuramah orang yang berkenaan, kaji selidik kepada pekerja di kawasan yang dinyatakan dan pengukuran teknikal. Data akan dikumpul menggunakan peralatan berkaitan seperti Digital Sound Level Meter. Tahap standard piawai pendedahan bunyi di kawasan yang dinyatakan dikaji dan dibandingkan dengan data yang diperolehi dalam keputusan kajian ini.keputusan yang ditunjukkan akan dipertingkatkan dengan beberapa cadangan untuk mengurangkan atau memperbaiki masalah. i

ABSTRACT This report is provided to explain a study of safety and health awareness among worker and noise assessment at stamping die company. This study covers the Occupational Safety and Health Administration (OSHA), OSHA 1994, hazard, noise exposure and noise improvement at Miyazu Malaysia Sdn Bhd (MMSB). This study carried out survey regarding to level of awareness among worker to Safety and Health in the workplace.this study also about noise level produces by machine compare to OSHA standard. The data was obtained from several methodologies includes observation, interview the authorized person, questionaire among worker in specified area and technical measurement. The data were collected by the related equipment such as Digital Sound Level Meter. The standard level of exposure on the focused area studied and compared with current value that obtained in this study.the result show will be improved by some recommedation to minimized or eliminated the problem. ii

DEDICATION To my beloved family thanks for continuous support to me in performing this difficult task, and the journey does not end here. To my supervisor, Mr. Al Amin bin Mohamed Sultan and Co- Supervisor, Mr. Mohd Shahrizan bin Othman for being receptive and critical, and challenging me to be a better student. To all course mate, for always support me, and also to my entire friend, for their sacrifice, encouragement, and support towards project accomplishment. Thank You iii

ACKNOWLEDGEMENT Utmost gratefulness to The Almighty ALLAH SWT for the abundant blessing and favours for me to accomplished the research Projek Sarjana Muda. I would like to extend my warmest gratitude to my supervisor and my co- supervisor, Mr. Al Amin bin Mohamed Sultan and Mr. Mohd Shahrizan bin Othman for their excellent supervision, invaluable guidance, advice trust, constant help, support, encouragement and assistance towards me throughout this project. I would also like to thank Miyazu Malaysia Sdn Bhd, and their staff as they provided me to make data collection, and always shows their sincere kindness in helping and gave me useful information. Ina addition, I would like to thank my family whose endless encouragement gave me the added strength and inspiration to carry out this project to the best of my ability. At the same time, I would like to thank my friends and course mate for their constructive comments throughout the accomplishment of this project. iv

TABLE OF CONTENT Abstrak Abstract Dedication Acknowledgment Table of Content List of Tables List of Figures List Abbreviations, Symbols and Nomenclatures i ii iii iv v ix x xii CHAPTER 1: INTRODUCTION 1 1.1 Background of study 1 1.2 Problem Statement 2 1.3 Objective 3 1.4 Scope of project 4 1.5 Importance of Study 4 1.6 Report Outline 5 1.7 Summary 5 CHAPTER 2: LITERATURE REVIEW 6 2.1 Occupational Safety and Health Administration (OSHA) 6 2.1.1 Objective of OSHA 8 2.1.2 Occupational Safety and Health Act 1994 8 2.1.3 Scope of OSHA 1994 10 2.1.4 Objective of OSHA 1994 10 2.1.5 Principles of OSHA 1994 10 2.2 OSHA Issues in Manufacturing Company 11 2.3 Hazards in Workplace 12 2.3.1 Safety and Health Hazard 13 2.4 Noise Hazard 13 v

2.4.1 Definition of Noise 14 2.4.2 Noise Exposure 15 2.4.3 Noise Level Equipment 18 2.5 Noise Prevention 19 2.6 Previous Case Study Noise Exposure 24 2.7 Summary 28 CHAPTER 3: METHODOLOGY 29 3.1 Project Overview 29 3.1.1 Process Flow Chart 30 3.2 Methodology 31 3.3 Primary Data 31 3.3.1 Interview 32 3.3.2 Observation 32 3.3.3 Questionnaire 32 3.4 Secondary Data 33 3.5 Data Collection 33 3.5.1 Design of Questionnaire 34 3.5.2 Design of Interview 36 3.5.3 Noise Level Measurement 37 3.6 Data analysis 39 3.6.1 Statistical Method 39 3.7 Suggestion and Recommendation 40 3.8 Company Background 41 3.8.1 General Information 42 3.9 Gantt Chart 43 3.10 Summary 44 CHAPTER 4: RESULT & DISCUSSION 45 4.1 Introduction to Data Collection 45 4.2 Results and Data Analysis of Questionnaire 46 4.2.1 Personal Information 46 4.2.1.1 Gender 46 vi

4.2.1.2 Working Experience 47 4.2.1.3 Working Hours 47 4.2.1.4 Types of Risks 48 4.2.2 Work Environment Issues 49 4.2.2.1 Work Environment and Noise Exposure 49 4.2.2.2 Dust and Lighting 50 4.2.2.3 Personal Protective Equipment 51 4.2.2.4 Health Quality and Accident 52 4.2.2.5 Health Screening 53 4.2.3 Safety and Health Awareness 54 4.2.3.1 Safety and Health Quality 54 4.2.3.2 Level of Safety and Health Policy 54 4.2.3.3 Safety Exposure and Safety Awareness 55 4.2.3.4 Occupational Safety and Health Act (OSHA) 56 4.2.3.5 Safety Instruction and Safety Campaign 56 4.2.3.6 Health Care by Employer 57 4.2.3.7 Social Security Organization (SOCSO) 58 4.2.3.8 OSHA Information 58 4.3 Result of Interview Session 59 4.4 Result of Observation 62 4.5 Result and Data Analysis of Noise Assessment 64 4.6 Discussion 72 4.6.1 Level of Awareness OSHA 72 4.6.2 Work Environment and Health Issues 74 4.6.3 Noise Assessment 75 4.7 Suggestion of Safety and Health Issues 78 4.8 Suggestion of Noise Improvement 79 4.8.1 Hearing Protection 79 4.8.2 Enforcement by the Administration 79 4.8.3 Machine Improvement 82 vii

CHAPTER 5: CONCLUSION & RECOMMENDATION 83 5.1 Conclusion 83 5.2 Recommendation 84 REFERENCES 85 APPENDICES 86 viii

LIST OF TABLES 2.1 Difference between FMA 1967 with OSHA 1994 9 2.2 OSHA s Permissible Noise Exposure 16 2.3 Some commonly used engineering controls 20 3.1 Step in Designing Questionnaire 34 3.2 Types of Information 35 3.3 Gantt Chart 43 4.1 Types of Risks Percentages 48 4.2 Interview Session Result 60 4.3 Findings of Observation 62 4.4(a) Average Noise Level for Day 1 65 4.4(b) Average and Variance for Each Machine 65 4.4(c) Summary of ANOVA Result 65 4.5(a) Average Noise Level for Day 2 66 4.5(b) Average and Variance for Each Machine 66 4.5(c) Summary of ANOVA Result 67 4.6 T-test Result 67 4.7 F-test Result 68 4.8 Part 1 (Noise Comfortable) 69 4.9 Part 2 ( Noise Level Awareness and PPE) 70 4.10(a) Part 3 (PPE) 70 4.10(b) Part 3 (PPE) 71 4.10(c) Part 3 (PPE) 71 4.11 Percentage every needs aspects of Safety and Health 72 ix

LIST OF FIGURES 2.1 Elements: Occupational Health 7 2.2 Typical Noise Levels in Manufacturing Sector 17 2.3 A modern sound level meter 18 2.4 A noise dosimeter 19 2.5 Sound Curtain or Sound Blankets 21 2.6 Composite Foam 21 2.7 Hearing Protection Devices 23 3.1 Process Flow Chart 30 3.2 Specifications Digital Sound Level Meter Model 407730 37 3.3 Noise Measurement Mapping Diagram 38 4.1 The Types of Data Collection 45 4.2 The Distribution by Gender 46 4.3 The Distribution by Working Experience 47 4.4 The Distribution by Working Hours 47 4.5 The Distribution by Types of Risks 48 4.6 Comfort with Work Environment Percentages 49 4.7 Comfort with Noise Exposure Percentages 50 4.8 Comfort with Dust Percentages 50 4.9 Comfort with Lighting Percentages 51 4.10 Wearing PPE during work Percentages 51 4.11 Health Quality Percentages 52 4.12 Accident during work Percentages 52 4.13 Health Screening Percentages 53 4.14 Safety and Health Policy Percentages 54 4.15 Level of Safety and Health Policy Percentages 54 4.16 Level of Safety and Health Policy Percentages 55 4.17 OSHA Percentages 56 x

4.18 Safety Instruction Percentages 56 4.19 Health Care by Employer Percentages 57 4.20 SOCSO Percentages 58 4.21 OSHA Information Percentages 58 4.22 Plant Machinery Layout 64 4.23 Graphical Comparison of Noise Level between Day 1 and Day 2 69 4.24 Level of Awareness Diagram 73 4.25 Noise Mapping Layout 79 4.26 Noise Mapping Layout with Hearing Protection 81 4.27 Sample of Silencers 82 xi

LIST OF ABBREVIATIONS, SYMBOLS AND NOMENCLATURE OSHA - Occupational Safety and Health Administration PPE - Personal Protection Equipment DOSH - Department Occupational Safety and Health FMA - Factory and Machinery Act WHO - World Health Organization ISO - International Organization for Standardization TWA - Time weighted average ANSI - American National Standard Institute PSM - Projek Sarjana Muda MMSB - Miyazu Malaysia Sdn Bhd ANOVA - Analysis of Variance xii

CHAPTER 1 INTRODUCTION This chapter describes the introduction section of the report. It contains the problem statement, objectives, importance of study and scope. This chapter also describes background of study that related to the problem statement. 1.1 Background of study Working workplace must be safe and comfort for all workers to work. A good working environment will increases productivity and efficiency the company. Sanjeev (2005) defines a safety working environment is the workplace has been assessed for hazards and the hazards are eliminated or controls have been implemented so that the company is able to operate safely. A hazard is a source or potential source of human injury, ill health or disease (Comcare, 2005). Hazard also can be defined such as anything will cause to injury or ill health at workplace. Some hazards are easy to identify and obvious but others are not for example, exposure to noise, poor lightning, chemicals and etc. All worker need to be aware of the issues that will be effect on their health and safety at the workplace. In other hand, the worker have to work in good environment where risk to their safety and health are properly controlled. 6

However, worker and employee have a legal responsible to look after safety and health at workplace. Safety and health management system and programs are designed with the purpose of ensuring the safety, health and welfare of person at work and protection to other people from hazards to safety and health arising from the activities of person at work. The sound is also play an important part in our environmental especially in the workplace area. The unwanted sound will become a noise to human hearing and effect the human peacefulness. The high noise can cause human to lose their hearing ability that is very important in human life. In the short term, the noise did not bring any side effect to us but in the long term it can possibly hurt our hearing (Ahmad, 2008). Because of that, this study was conducted to identify the level of awareness worker about Occupational Safety and Health Administration (OSHA) regarding to hazard at workplace. Besides, noise level exposures were access in order to reduce unwanted sound in the industry. This study is done in the working area at Miyazu Malaysia Sdn Bhd (MMSB), which is one of the parts of stamping die industry. 1.2 Problem Statement Safety and Health issues are important in industries sector. Employer has responsible to ensure their worker comfort and safe during work. Industries selected for this study involved manufacturing sector which include stamping die, plastic mould, module assembly, engineering services and production services. This company is required to adhere to the requirements of the OSHA 1994 but it will be interesting to know how the level of awareness worker about Occupational Safety and Health Administration (OSHA) and hazards in stamping die workplace. In order to measure the safety and health awareness among worker, it is importance to know condition of workplace in the stamping die company. 7

Besides, worker of this company also exposed to noise but the stamping die areas which exceed the OSHA standard is not identified. From that, it concern to know the noise level in the specified area. In addition, worker of these company not wear any Personal Protection Equipment (PPE) such as ear plug or ear muff were they are exposed to noise during work. But, the PPE are provided. 1.3 Objectives Three specific objectives have been simplified of this study. There are: i) To assess the safety and health awareness among stamping die company worker ii) To analyze the noise level of machine refers to OSHA standard. iii) To suggest the proper solution according to excessive noise level at stamping die company 1.4 Scope of Project This study was focused on the level of safety and health awareness worker at workplace. Interview and questionnaire conducted to evaluate the level of awareness regarding to OSHA and hazard during visit the company. A questionnaire consists 22 question have been prepared for 30 workers. Noise level at this company was measured using Digital Sound Level Meter and collected for each machine at Tooling Plant workplace. Based on the measurement, the most critical noise level is identified and the proper solution suggested. Besides, noise mapping are used to identify which area are most critical exposed to noise. A questionnaire also used in noise assessment to find relationship between noise measurement and comfortable of worker to noise at workplace. Then, some suggestions are proposed to reduce the entire problem. In addition, this study focused on the work environment in Miyazu Malaysia Sdn Bhd (MMSB) at Tanjung Malim, Perak. 8

1.5 Importance of Study Regarding to this study, some benefits are give to the several parties such as company employer, company worker and student. From employer view, this project can help company to change their work environment based on safety and health issues. Besides, the company can increase productivity, reduces injury and comfortable of working environment. This study also may help the worker of company to protect their health. The worker may change the workstation or workplace while they do the job and it will give the comfortable for them. In addition, this study also gives benefits to student to increase the ergonomic knowledge based on real situation in manufacturing working area. The student also exposed and applied the technical measurement based on hands on practice such as noise level assessment. 1.6 Report Outline Chapter 1 introduces the project which is including objectives, problem statement and scope of project. In this chapter, it describes the study on working environment which is related to Occupational Safety and Health Administration and hazard in the company. Chapter 2 describes the literature review on definition of OSHA and hazard and the theoretical of health hazard, noise exposure, and definition of noise, method to measure noise level and noise prevention method. Chapter 3 represents the flow chart that carried out for the whole process of the methodology such as in gathering information, collecting data and result evaluation of the study. In this chapter, it also explained the company background of the study. 9

Chapter 4 represents development the data collection by using methods of questionnaires, interview and observation. The results are analyzed and discussed by constructed the measurement by using Microsoft Office Excel software. Besides, this chapter discuss about suggestion for the improvement regarding to problem statement. Chapter 5 describes the conclusion and recommendation for future work. 1.7 Summary This chapter is introducing the project background and the objective of the project. In addition, the problem statement and scope of study also being clarify in order to limit the range of this project conduct. The following chapters consist of the literature review and knowledge that required in conducting the whole study. 10

CHAPTER 2 LITERATURE REVIEW This literature review explores the dominant themes includes study and research of published materials like journals, thesis, case study, technical document, and online library. Generally, the purpose of a review is to analyze critical segment of a published body of knowledge through summary, classification and comparison of prior research studies, reviews of literature, and theoretical articles. This chapter will describe topics that related topic such as Occupational Safety and Health (OSHA), definition of hazards and theory of health hazards. It also describes about noise exposure and theory of noise such as definition of noise, noise equipment and suggestion from previous study to prevent noise exposure. 2.1 Occupational Safety and Health Administration (OSHA) Occupational safety and health is a major concern to many countries. A simple definition of occupational safety and health (OSH) in respect of a place of work or person at work is, the state of being safe or the absence of factors that could lead to accidents, injuries or interruptions to work Occupational Safety and Health Act (OSHA) is an act to make further provisions for securing the safety, health and welfare of persons at work, for protecting others against risks to safety or health in connection with the activities of persons at work, to establish the National Council for Occupational Safety and Health, and for matters connected therewith (Alwi, 2011,pp4). 11

Goetsch (2008,p13) describes the Occupational Safety and Health Administration (OSHA) is the government s administrative arm for the Occupational Safety and Health (OSH Act).Formed in 1970, OSHA sets and revokes safety and health standards, conduct inspections, investigates problem, issues citations, assesses penalties, petitions the courts to take appropriate action against unsafe employers, provides safety training, provides injury prevention consultation and maintains a database of health and safety statistics. According to Tatiya (2011) Occupational Safety and Health is traditional way to deal with legislation, regulation, standards, safety guidelines, accident investigations and safety inspections which provide information on causes of accidents amongst particular groups of employees. There are four elements in Occupational Health. Figure 2.1 shows the relationship between four elements of Occupational Health. Cray and Mendeloff (2002) state OSHA does tens of thousands of inspections, and imposes millions of dollars in penalties each year, but most workplaces are only rarely visited, penalties are low relative to the cost of abating many workplace hazards, and many injuries are unrelated to OSHA standards. Figure 2.1: Elements: Occupational Health (Tatiya, 2011) 12

Nowadays, environmental in industries can be a great danger to human if not controlled properly. All the danger can be called hazards. According to the OSHA rules and regulation, the environmental hazards can be minimized in order to protect the worker and the general public. OSHA standards have required conditions or adoption or use of one or more practices, methods or process to protect workers on the job and to endure that worker have and use personal protective equipment (PPE) when required for safety. The general duty of the OSH Act requires that employee provide a workplace that free from hazards. (Geotsch, 2008, pp91) 2.1.1 Objective of OSHA In order to prevent worker from injuries and illness, OSHA have their own objective to achieve. The main objectives of OSHA are implemented in the company so that employees can enjoy a better work place, safe and healthy by making and enforcing laws and standards for safety and health at work. Cray and Mendeloff (2002) state the mission of the Occupational Safety and Health Administration (OSHA) is to promote the safety and health of America s working men and women and part of this mission is a goal to reduce workplace injuries. OSHA may impact workplace injuries through one or more mechanisms. OSHA also allows the enforcement of certain standards needed to protect workers. In addition, it seeks to prevent employees from making works that may cause injury, illness and death. 2.1.2 Occupational Safety and Health Act 1994 (Malaysia) According to DOSH (2006), Occupational Safety and Health Act (OSHA) were enforced in Malaysia on 25th February 1994 with the intent to ensure safety, health and welfare of all persons at all places of work. The Act also provides for a consultative process at the policy level with the establishment of Nation Council for Occupational Safety and Health. This consultative process extends to where safety and health programs are implemented with both employers and employees representative as members of safety and health committee. 13