IR. DR.

MOHAMAD SHAIFUL ASHRUL ISHAK

PHONE :019-2775019
TWITTER : @encek_sepul
BFT 563 PROFESSIONAL PRACTISE
IN ENGINEERING MANAGEMANT

Semester I
AS 2018/19
CHAPTER 3 SAFETY & HEALTH ISSUES
IN PROJECT MANAGEMENT
 HAZARDS ID WHAT IS OSH

WHY OSH - BENEFITS

CLASSIFY HAZARDS

CONSEQUENT OF HAZARDS- WHAT CONSTITUTE OSH

HEALTH
ROUTES
DIFFERENTIATE HEALTH &
FACTORS/EFFECT CONTROL - BREIFLY SAFETY
LEGAL

IMPLICATION
QUALITATIVE MORAL & ETHIC
RISK MANAGEMENT AND
RISK ASSESSMENT
SAFETY FINANCIAL

SAFETY CULTURE
COSTS
QUANTITATIVE

ACTS HIRARC - TOOL

STEPS IN HIRARC
OSH 1994

RISK CONTROL RISK MONITORING

FAC & MACH 1967

ELIMINATION ENGINEERING
MINIMIZATION ADMINSTRATIVE
 Safety and Health – how it evolved

• PREVIOUSLY, EMPLOYERS NOT CONCERN FOR SAFETY OF

WORKERS & IN FACT LITTLE INCENTIVE TO BE CONCERNED.
SAFETY PROGRAMS WERE IN FACT NONEXISTENT.

• WHEN THE INDUSTRY IN THE WEST FACED WITH LABOR

SHORTAGES ESPECIALLY DURING WW1 AND WW2,
EMPLOYERS COULD NOT EFFORT TO LOSE WORKERS TO
ACCIDENTS OR ANY OTHER REASONS.

•THIS LED TO GREATER OPENESS TO PROVIDING SAFETY A

SERIOUS CONSIDERATION BY EMPLOYERS
 Safety and Health – how it evolved

• INDUSTRY BEGAN TO REALIZED THAT:

• IMPROVED ENGINEERING COULD PREVENT ACCIDENTS
•EMPLOYEES WERE WILLING TO LEARN & ACCEPT SAFETY RULES
•SAFETY RULES COULD BE ESTABLISHED AND ENFORCED
•FINANCIAL SAVING FROM SAFETY IMPROVEMENT COULD BE REAPED BY
SAVING IN COMPENSATION AND MEDICAL BILLS

•WITH THESE REALIZATION AND INCENTIVES, EMPLOYERS

BEGAN TO PLAY ACTIVE ROLE IN CREATING AND
MAINTAINING SAFETY AT WORKPALCE – THERE IS
ORGANIZED SAFETY PROGRAMS
 Safety and Health – how it evolved
• THE ENGINEERING ASPECTS – DESIGN IMPROVEMENT THAT
SIMPLIFIED MANUFACTURING PROCESS, MADE LESS DANGEROUS.
MANUFACTURING PROCESS IS ENGINEERED IN WAYS THAT REDUCE
POTENTIAL HAZARDS.

• EDUCATION ASPECTS – SAFETY PROGRAM ENSURES EMPLOYEE

KNOW HOW TO WORK SAFELY, WHY IT IS IMPORTANT TO DO SO,
AND SAFEY IS EXPECTED BY MANAGEMENT

• ENFORCEMENT ASPECTS – SAFETY PROGRAM MKING SURE

EMPLOYEE ADIBE BY SAFETY POLICIES, RULES, REGULATIONS,
PRACTICES & PROCEDURES
Safety and Health – how it evolved

• THEY ARE MANY DIFFERENT TYPES OF ACCIDENT

PREVENTION PROGRAMS IN MODERN WORKPLACE

• THE WIDELY USED TECHNIQUES IN ACCIDENT

PREVENTION PROGRAMS SUCH AS FAILURE
MINIMIZATION, FAIL-SAFE DESIGN, ISOLATION,
LOCKOUT, ETC ARE INDIVIDUAL COMPONENTS OF A
BROADER SAFETY PROGRAMs THAT HAVE EVOLVED
OVER THE YEARS (since 1800s).
 Safety and Health ….the terms
• Safety means preventing accidents or
hazards from occuring

i.e Safety ÅÆ Accident

• Health means a state of complete
psychic, mental and social well being not
merely consist of an absence of disease
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 Hazard
HAZARD –condition with the potential of causing:

• Injury
• Diseases
• Damage to equipment or structures
• Loss of material or lessening of the ability to perform
a prescribed function
• Damage to the environment
• Or a combination of the above

- It is something that can cause harm if not

controlled
- the outcome is the harm that results from an
Workers don’t create hazards.
Hazards are often built into workplace.

Work processes can be designed to prevent

accidents and illnesses. Existing hazards
should be removed from the workplace.
When hazard is present, the
possibility of these adverse effect
(such as injury, diseases, damage
to equipment etc) occuring
exists…. RISK

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 so….. Safety
Frequently defined as “freedom from hazard”

- NOTE: It is practically impossible to eliminate all

hazards.

- Safety is therefore a matter of relative protection

from exposure to hazards (the antonym to
danger)

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 What is Accident?
• Unwanted and undesirable
• Unexpected
• Involves a deviation from what was intended, i.e.
a planned safe operation
• Involves injury to people and/or damage to plant
and equipment or materials, including the
finished product - or at least the potential for
injury/damage (an event labeled a ‘near
miss accident’)
• Involves a chain of events, rather than one isolated
event
 Milestones in the safety movement in
MALAYSIA

1890 - Boiler Enactment 1890.

1 legislation in the country to
st

address safety issues. Mandatory

inspections of boilers by the
Mines Department inspectors.
 Milestones in the safety movement in
MALAYSIA
1913- Machinery Ordinance 1913. Superseded all the
Boiler Enactment.
1932- Machinery Enactment 1932. Updated.
Addition on provision on registration and
inspection of machinery installation. Enforced by
Dept. of Mines.
1953- Machinery Ordinance 1953. Superseded all
previous Regulations. 4 Regulations were enacted,
one was Safety and Health and Fire 1953;
Enforced by Dept of Machinery, Min of Labor.
 Milestones in the safety movement in
MALAYSIA
1967- Factory and Machinery Act 1967.
Superseded Machinery Ordinance 1953.
Fill the gaps, cover all aspects on industry – safety
and health in all work place defined as factories
(before, people worked in workplace where there
was no machinery were unprotected).
BUT work force under agriculture, forestry, fishing,
construction, finance and public services not
protected. Enforced by Factory and Machinery Dept.

1970- Regulations.
 Milestones in the safety movement in
MALAYSIA

1991- Bright Sparklers factory explosion in

Sungai Buluh killed 22 workers. Stiffer
penalties to employers failed to safeguard
workers.
{Bhopal tragedy in India 1984 (3000
killed, 50,000 suffered disability &
Chernobyl nuclear power disaster in
Russia 1986}.
 Milestones in the safety movement in
MALAYSIA
1994- Occupational Safety and Health Act (OSHA).
To meet Malaysian fast economic growth to
become an industrialized state by 2020 .
Plug the weakness of 1967 Act.
Provide general guidelines how to create a safe
environment at work.
All protected.
Except those working on board ships (Merchant
Shipping Ordinance 1952, Merchant Shipping
Ordinance (Sabah & Sarawak) 1960.
 Milestones in the safety movement in MALAYSIA
1890 - Boiler Enactment 1890. 1st legislation in the country to address safety issues.
Mandatory inspections of boilers by the Mines Department inspectors.
1913- Machinery Ordinance 1913. Superseded all the Boiler Enactment.
1932- Machinery Enactment 1932. Updated. Addition on provision on registration and
inspection of machinery installation. Enforced by Dept. of Mines.
1953- Machinery Ordinance 1953. Superseded all previous Regulations. 4 Regulations were
enacted, one was Safety and Health and Fire 1953; Enforced by Dept of Machinery,
Min of Labor.
1967- Factory and Machinery Act 1967. Superseded Machinery Ordinance 1953. Fill the
gaps, cover all aspects on industry – safety and health in all work place defined as
factories (before, people worked in workplace where there was no machinery were
unprotected). BUT work force under agriculture, forestry, fishing, construction,
finance and public services not protected. Enforced by Factory and Machinery Dept.
1970- Regulations.
1991- Bright Sparklers factory explosion in Sungai Buluh killed 22 workers. Stiffer penalties
to employers failed to safeguard workers. {Bhopal tragedy in India 1984 (3000 killed,
50,000 suffered disability and Chernobyl nuclear power disaster in Russia 1986}.
1994- Occupational Safety and Health Act (OSHA). To meet Malaysian fast economic
growth to become an industrialized state by 2020 . Plug the weakness of 1967 Act.
Provide general guidelines how to create a safe environment at work. All protected.
Except those working on board ships (Merchant Shipping Ordinance 1952, Merchant
Shipping Ordinance (Sabah & Sarawak) 1960.
 Lessons Learnt from Bhopal tragedy?
40 tons of methyl isocyanides (MIC) and other lethal gases including
hydrogen cyanide leaked. Morning of 3rd December 1984. Accident – is
a series of event (http://www.ehjournal.net/content/pdf/1476-069X-4-6.pdf)

Protective equipment – that could stop the disaster not in full

working order
Refrigeration system – to cool the storage tank was shut down.
Scrubbing System – to absorbed the vapor was not
immediately available.
Flare system – to burn any vapor that got past the
scrubbing system was out of order.

(source: Goetsch, 2011).

 Lessons Learnt from Bhopal tragedy?

Supreme Court India ordered USD470 millions compensation.

The fund were paid to Indian Government to compensate the
victims. LINK - http://www.bhopal.com/~/media/Files/Bhopal/chrono_2012_3.pdf

Criminal negligence
Corporate prejudice – chose a poverty-stricken country as a
location that few would care if something went wrong
Avoidance – putting a plant in remote area/poor country to avoid
stricter safety and health standards of the country that of the
parent company.

In US, it led to the passage of - Emergency Planning and

Community-to-know Act (EPCRA) in 1986 (Goetsch, 2011).
 STATISTICS

FATALITY
AND ACCIDENTS
IN WORK PLACE
http://www.dosh.gov.my/

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RATES OF OCCUPATIONAL ACCIDENTS in
MALAYSIA on 2015 (Sorted by Sector)

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RATES OF OCCUPATIONAL ACCIDENTS in
MALAYSIA on 2015 (Sorted by State)

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 SAFETY ALERT 2016

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CHALLENGES OF INDUSTRIAL
ACCIDENTS
• Industrial Accidents is on the decline but
the compensation paid is on the increase
• Accidents are more severe in nature and
have longer medical leave
• Minor accidents are not reported
• Total number of Commuting Accidents
increased by 9%
• Breakdown of Accident
Costs for the Industry
• The costs can be categorized
into
- Direct cost
- Indirect cost
• payment Direct
for workcosts
not performed;
• medical and compensation
payments;
• repair or replacement of damaged
machinery and equipment;
• reduction or a temporary halt in
production;
• increased training expenses and
administration costs;
• possible reduction in the quality of
work;
negative effect on morale in other
 Indirect costs
The costs of an accident or illness
can be 4 to 10 times greater than
the direct costs, or even more!

An occupational illness or accident

can have so many indirect costs to
workers that it is often difficult to
measure them. One of the most
obvious indirect costs is the human
suffering caused to workers' families,
which cannot be compensated with
money.
 Indirect costs
• the injured/ill worker has to be replaced;
• a new worker has to be trained and given
time to adjust;
• it takes time before the new worker is
producing at the rate of the original worker;
• time must be devoted to obligatory
investigations, to the writing of reports and
filling out of forms;
• accidents often arouse the concern of fellow
workers and influence labor relations in a
negative way;
• poor health and safety conditions in the
workplace can also result in poor public
relations.
 Challenges of Occupational
Diseases

• Reported OD cases for 2009 increased by 85 %

• Total number of OD is expected to increase due to long latency

period, before the disease manifests and individual
susceptibility factor

• New emerging diseases is on the increase

• Medical surveillance is not done according to the regulations for

early intervention and thus disease may appear later with much
more serious complication

• Under reporting phenomena

carpal
 SAFETY AND HEALTH PROGRAM – WHAT?
A workplace safety and health program is a
systematic plan to identify and control hazards
and respond to emergencies.

The program lays out responsibilities, resources,

and procedures for keeping the workplace safe and
healthy.

Its objective is to integrate safety and health into

all work practices and conditions.
 SAFETY AND HEALTH PROGRAM – WHY?

Why Managing Safety and Health?

Mandatory under the law ….the OSH Act

It is one of the general duties as prescribed

under the Occupational Safety and Health
Act 1994 (Act 514) for the employer to
provide a safe workplaces to their employees
and other related person.
OSHA 1994 Requirement

For all industries

�If >5 Employees -Safety & Health Policy
�≥40 Employees (S30) -Safety & Health Policy + Safety &
Health Committee

For high risk industries (i.e. construction, ship building, gas etc.)
�>100 Employees -Safety & Health Policy + Safety &
(Order 1997) Health Committee + a Certified
Safety & Health Officer

For low risk industries (other than the above mentioned industries)
�>500 Employees -Safety & Health Policy + Safety &
(Order 1997) Health Committee + a Certified Safety &
Health Officer
 Why Managing Safety and Health?

Since the days of the Industrial

Revolution, when most factories were
death-traps for the workers, legislation
has steadily improved health and safety
at work.

Applying our normal principle that

prevention is better than cure.
http://www.ehcareers.org/about/specialist_environmental_protection.html
Why Managing Safety and Health?
• Moral and Ethical Issues
-Respect Human Resources - morale, commitment, image
-Respect their family – pride,
- Ethical Issues AS A PROFESSIONAL
• Legal Issues (MACHINERY AND FACTORY ACT 1967; OSH ACT
1994
-Claims for compensation
-Disruption during the legal process
• Financial Issues - is not a JUST legal, moral and ethical
obligation; it also makes good business sense!!!!!.
-Increase of Insurance Premium
-Direct Lost
-Indirect Lost
FACTORIES ACT 1967
THE ACTS - two most important

OSHA ACT 1994

 LEGAL REQUIREMENTS UNDER OSHA 1994

WHAT ARE THE PROVISION UNDER THE

OCCUPATIONAL
SAFETY AND HEALTH
ACT 0F 1994
 LEGAL REQUIREMENTS UNDER OSHA 1994

Do you know that it is the duty of our EMPLOYER under the

Occupational Safety and Health Act 0f 1994 to:

a) Ensure our safety, health and welfare at our workplace by:

• the provision and maintenance of plant and systems of work that are
safe and without risks to health;
• making of arrangements for ensuring safety and absence of risks to
health in connection with the use or operation, handling, storage and
transport of plant and substances;
• the provision of such information, instruction, training and
supervision as is necessary to ensure the safety and health at work;
• maintaining the workplace in a condition that is safe and without risks
to health and the provision and maintenance of the means of access
to and egress from it that are safe and without such risks;
• the provision and maintenance of a working environment which is
safe, without risks to health and adequate as regards to facilities for
our welfare at work.
 LEGAL REQUIREMENTS UNDER OSHA 1994

b) Formulate safety and health policy:

as often as may be appropriate revise a
written statement of his general policy
with respect to the safety and health at
work;
arrangements for the time being in force
for carrying out the policy;
to bring the statement and any revision of
it to the notice of all of his employees.
 LEGAL REQUIREMENTS UNDER OSHA 1994

c. Employ a competent person to act

as a Safety and Health Officer at the
place of work exclusively for the
purpose of ensuring the due
observance at the place of work of the
provisions of the OSHA and its
regulations and the promotion of a
safe conduct of work at the place of
work.
 LEGAL REQUIREMENTS UNDER OSHA 1994

d) Establish a Safety and Health

Committee at the place of work if
there are 40 or more persons
employed at the place of work
 LEGAL REQUIREMENTS UNDER OSHA 1994

e) Consult the Safety and

Health Committee with a view to the making
and maintenance of arrangements which will
enable him and his employees to co-operate
effectively in promoting and developing
measures to ensure the safety and health
at the place of work of the employees and
in checking the effectiveness of such
measures.
 LEGAL REQUIREMENTS UNDER OSHA 1994

f) Notify the nearest Occupational Safety

and Health Office of any accident,
dangerous occurrence, occupational
poisoning or occupational disease which has
occurred or is likely to occur at the place
of work.
 LEGAL REQUIREMENTS UNDER OSHA 1994

g. General duties of employers and

self-employed persons to persons
other than their employees.

It shall be the duty of every employer and

every self-employed person to conduct his
undertaking in such as manner as to
ensure, so far as is practicable, that he and
other persons, not being his employees,
who may be affected are not thereby
exposed to risks to their safety or health
 LEGAL REQUIREMENTS UNDER OSHA 1994

g. General duties of manufacturers, etc as

regards plant for use at work.

(1) It shall be the duty of a person who designs, manufactures, imports or

supplies any plant for use at work-
(a) to ensure, so far as is practicable, that the plant is so designed and
constructed as to be safe and without risks to health when properly used;
……..
(2) It shall be the duty of a person who undertakes the design or manufacturing
of any plant for use at work to carry out or arrange for the carry out of any
necessary research with the view to discovery and, so far as practicable, the
elimination or minimization of any risk to safety or health to which the design or
plant may give rise.
 LEGAL REQUIREMENTS UNDER OSHA 1994

Nevertheless, it is our duty as employees to:

a) Take reasonable care for the safety and health of
ourself and of other persons who may be affected by our
acts or omissions at work;
b) Co-operate with our employer or any other person in
the discharge of any duty or requirement imposed on our
employer or that other person by OSHA;
c) Wear or use at all times any protective equipment or
clothing provided by our employer for the purpose of
preventing risks to our safety and health;
d) Comply with any instruction or measure on occupational
safety and health instituted by our employer or any other
person by or under OSHA or any regulations made
thereunder.
 LEGAL REQUIREMENTS UNDER OSHA 1994

WHAT ARE THE PROVISION UNDER THE

FACTORY AND
MACHINERY ACT,
1967
 FACTORY AND MACHINERY ACT, 1967

Part II. SAFETY, HEALTH AND WELFARE

Provisions relating to safety, etc

10. Without prejudice to any law with respect to

local authorities, in respect oaf any factory, the
following provisions relating to safety shall apply:
(a) foundation and floor…..
(e) every openings, sump, pit or fixed
vessel in a floor , or working level shall be
securely fenced so as to prevent risk of persons
falling;….
 FACTORY AND MACHINERY ACT, 1967

Part II. SAFETY, HEALTH AND WELFARE

Persons exposed to explosive, inflammable, etc.,
substances
11. In a factory in which persons are exposed to
risk of bodily injury from explosive, inflammable,
poisonous or corrosive substances or ionizing
radiations, such measures as may be prescribed
shall be taken as will eliminate the risk.
 FACTORY AND MACHINERY ACT, 1967

Part II. SAFETY, HEALTH AND WELFARE

Lifting of weights

12. No person shall be employed to lift, carry or

move any load so heavy as to be likely to
cause injury to him
 FACTORY AND MACHINERY ACT, 1967

Part II. SAFETY, HEALTH AND WELFARE

Construction of machinery

14. All machinery and every part thereof including all

fittings and attachment shall be of sound
construction and sound material free from defect
and suitable for the purpose and shall be properly
maintained
 FACTORY AND MACHINERY ACT, 1967

Part II. SAFETY, HEALTH AND WELFARE

Projecting material

16. In respect to such machinery as may be

prescribed, any part of any material carried by
that machinery while it is working thereon which
projects beyond any part of the machinery
shall be effectively fenced unless it is in such a
position as to be safe to any person employed
or working on or renting the premises.
 FACTORY AND MACHINERY ACT, 1967

Part II. SAFETY, HEALTH AND WELFARE

Machinery manufactured or repaired must
comply with regulations

18 (1) No person shall

manufacture, repair or install
machinery in such a manner
that it does not comply with
the provisions of this Act and
any regulations made
thereunder applicable to such
machinery
 FACTORY AND MACHINERY ACT, 1967

Part II. SAFETY, HEALTH AND WELFARE

Provisions relating to health
22 (1) Without prejudice to any law to public health,
in respect of any factory the following provisions
relating to health of persons shall apply:

(a) every factory shall be kept in a clean state and

free from offensive effluvia arising from any
drain, sanitary convenience or other source …
(b) the maximum number of persons employed at
any one time in any work-room in any factory
shall be such that the amount of cubic feet of
space and superficial feet of floor area allowed in
the work-room for each person are not less than
the amount of cubic feet of space and superficial
feet of floor area prescribed either generally or
for the particular class of work carried on in
the work-room
PROVISION OF SAFE AND HEALTHY
WORK ENVIRONMENT THAT
ACCIDENTS AND ILLNESS CAN BE
PREVENTED IS A VERY IMPORTANT
ASPECT
IN ENGINEERING PROFESSION

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 Benefits of Good OSH
• Reduced lost time
• Reduced need to provide cover for personnel
absent from work because of injury
• Reduce sick pay payments
• Reduce need for time-consuming accident
investigation and consequent saving in management
time and production down-time

• Reduced potential for prosecution and other

enforcement action by authorities
• Reduction in the number of claims for
compensation by injured personnel
 Benefits of Good OSH …continue

• Reduced employer’s liability insurance

premiums
• Improved morals
• Improved image of company, both in terms
of employer and competent contractor

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 CASE STUDIES

ON

SUCCESSFULL
IMLPEMENTATION OF
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Case study – North Staffordshire Combined
Healthcare NHS Trust
The board found itself facing service improvement targets. Using new
corporate and clinical guidance, it set about taking a 'whole systems' approach
to managing corporate risk, giving one of its directors responsibility for the
leadership of health and safety for the first time. Health and safety was also
made a key item on the board agenda.
This has resulted in a much better integrated health and safety management
system that increases the opportunity to identify and manage all corporate
risks, and a much more open culture, improving reporting and monitoring. The
board actively promotes a culture that gives staff the confidence to report
incidents.

This has resulted in:

 incidence rates reduced by 16% over two years;
 insurance premiums reduced by 10% - financial implication.
Case study – British Sugar
The company had an excellent safety record and had no indication of the
devastating events that were to happen – in one year three deaths
occurred. Although health and safety had always been a business priority,
a change in focus was needed to achieve behavioural change. This
included:
 the CEO assigning health and safety responsibilities to all directors, and
monthly reports go to the board;
 creating effective working partnerships with employees, trade unions
and others;
 overseeing a behavioural change programme and audits;
 publishing annual health and safety targets, and devising initiatives to
meet them.

Results include:
 time lost to injuries reduced by 43% over a two year period;
 63% reduction in major issues over the course of a year;
 much greater understanding by directors of health and
Case study – Mid and West Wales Fire
and Rescue Service
To give health and safety a high priority, Mid and West Wales Fire and Rescue Service
recognised that it was critical for its leadership to demonstrate to its staff that
accountability for health and safety was a fundamental element in the success of its
overall service delivery. The director of service policy and planning was nominated as
the health and safety director for the service in order to clearly define the
importance this subject held within the organisation. The director implemented a
revised health and safety framework, which included a programme of fire station
visits to engage the workforce, and placed a renewed emphasis on improving
incident reporting, investigation and monitoring procedures.

The service has reported:

 £100,000 reduction in insurance liability premiums in one year through improved
corporate strategic risk management;
 50% reduction in sickness absence through work related injury over a two year
period;
 50% reduction in injury incidence rate over a three year period.
Case study – Sainsbury's
An external health and safety audit identified a need to develop a unified approach,
and also recommended more direction from the board, to develop an effective
strategy.
The result was a radical revision of the company's approach, including:
the group human resources director creating a health and safety vision, supported by
a plan with targets over three years;
training on health and safety responsibilities was introduced for all board directors.

This has resulted in:

the board providing a role model for health and safety behaviour;
 17% reduction in sickness absence;
 28% reduction in reportable incidents;
 improved morale and pride in working for the company;
 raising the profile of health and safety so it is becoming embedded in the
culture of the organization.

http://www.hse.gov.uk/leadership/casestudies-success.htm
TECHNICALLY , THE GOAL OF SAFETY
AND HEALTH PROGRAM IN WORK
PLACE IS TO ESTABLISH A SAFE
WORKING ENVIRONMENT

THANK YOU
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ASSIGNMENT 1

Students are required to prepare a risk

assessment report based on the 4 topics
discussed. Please select a topic based on case
study 1 or case study 2.