PROEIGHT BATU CAVES FACTORY SAFETY AUDIT REPORT

1.0 INTRODUCTION
A safety audit at Proeight Batu Caves factory was done on 12th July 2010. The audit done
covers the whole factory building. The audit started at about 245 pm and ended at about 515
pm.

2.0 OBJECTIVES
The objective of this safety audit is to identify health, safety, security and environmental issues
present at the factory, verify compliance with legal requirements and recommend improvements
that can be made.

3.0 SCOPE
The scope of the audit covers all health, safety, security and environment legal aspects,
code of practice and guidelines.

4.0 METHODOLOGY
The inspection was conducted through a site walkthrough with employees there and inspection
is made at all the areas in the building. Observations were made and pictures were taken as
evidence. Interviews with employees there were also conducted to get as many information
available and to get their feedback regarding HSSE issues.

5.0 FINDINGS
Based on the observations and interviews made during the audit, there are several issues that
need to be highlighted and require management attentions to improve the existing condition and
thus, reducing risk and provide safe working environment to the employees there. The findings
are as follows:
5.0.1 Work environment
Observation showed that storage and placement of all things still need to be improved as boxes
and stuff are placed everywhere. There is no designated area for pallet truck and trolley. In
respect to chemical fumes and particulates, lapping room, EDM room, silica carbide and carbon
room has no or inadequate exhaust fan. The fumes and particulate are strong and hazardous
for employee working inside the room.

5.0.3 Work procedures

A work procedure is available for air pressure test but there is absence of pre-start checklist
before performing the pressure test. A checklist should be developed as the test involved
pressure hazards which can cause accident if not properly checked. The checklist should
include all criteria that are required for safe operation of the test. No Hazard Identification, Risk
Assessment and Risk Control (HIRARC) have been done for every work activity done in the
factory.

5.0.2 Chemical management

Chemical management includes proper labelling of chemical container, proper storage area,
availability of chemical register and respective MSDS. Observation made shown that there is no
chemical register present but there is list of chemical MSDS available at the factory. There is
also no designated cabinet for chemical storage. Chemical Health Risk Assessment (CHRA)
has never been conducted at the factory.

5.0.4 Scheduled waste management

Scheduled waste is hazardous waste that cannot be disposed as other general waste. It must
be treated at a prescribed premise licensed by Department of Environment (DOE) before being
disposed. Notification to DOE of our scheduled waste as stated in Environmental Quality
(Scheduled Wastes) Regulation 2005 is not done yet. No segregation is made between general
waste and scheduled waste. There are no proper labelling, container and storage area as
outlined in the Regulation.

5.0.5 Personal Protective Equipments (PPE)

Reusable PPE is given to each employees and they kept it in their own locker. Reusable PPE
given are ear plug, safety spectacles and safety shoes. Disposable PPE is also provided which
is ear plug and N95 respirator. This respirator is used for carbon room and lapping room. N95 is
not suitable for lapping room as it only protect from particulate and not chemical vapour.

5.0.6 Safety Signage

Stairs leading to store on third floor also has no signage to warn about the steep stair. There is
also no signage for elevated barrier at store entrance door. No safety signage and PPE signage
at the wood cutting area.

5.0.7 Emergency response procedures

After walking through the factory and observation were made, it is found that there is no
evacuation procedures pasted at the second floor. It is unsafe condition in case of emergency.

5.0.8 Training
It is found out, after interviews were made with worker, they have been trained for fire
evacuation procedure. There is no training provided other than that.

6.0 RECOMMENDATION

6.0.1 Work environment

Housekeeping need to be done to reduce risk of slip, trip and fall. Merchandise and things that
is not for use should be dispose and things to be used to be stored properly. Lines indicating
designated area for pallet truck should be done to prevent the pallet truck placed improperly.
Occupational Safety and Health (Use and Standards Exposure of Chemicals Hazardous to
Health) Regulations 2000 suggested the installation of Local Exhaust Ventilation for chemical
hazards to reduce the concentration of vapour in a room.

6.0.2 Work procedures

A checklist will be developed with cooperation from QA/QC side. The checklist will take into
account all the safety requirements and criteria to be checked to ensure safe operation of the
test.

6.0.3 Chemical management

All chemical containers will be provided with proper chemical labelling according to
Occupational Safety and Health (Classification, Packaging and Labelling) Regulations 1997. It
will contain all the information required such as the hazards and safe handling procedures.
Chemical register will be developed and placed at the workplace along with list of each MSDS
used in the factory.

5.0.4 Scheduled waste management

Notification to DOE will be made for all of the generated scheduled waste as stated in
Environmental Quality (Scheduled Wastes) Regulation 2005. Notification to DOE will be made
using the form given in the Second Schedule of the Regulations. A monthly inventory will be
produced to keep date of schedule waste volume generated. Separate bin for general and
scheduled wastes will be provided for the factory. Label will be created and attached at the
scheduled waste container which shall contain name of company, date first generated,
telephone number and address of the company, and symbol as per Third Schedule. Proper
container and storage area should be provided for the scheduled wastes.

6.0.5 Personal Protective Equipment (PPE)

The types of respirator suitable such as P95, P99 (NIOSH classification) or FFP2 (EN149:2001)
will be looked into and buy for workers usage. The respirator should also been certified by
DOSH.

6.0.6 Safety signage

Safety signage for the stair leading to store, elevated barrier at store entrance door and wood
cutting area will be put up.

6.0.7 Emergency response procedures

Emergency evacuation procedures will be put up at strategic areas at each level and briefed to
all the employees there. Evacuation map will be put on at strategic areas at the factory which
will include emergency contact number.

6.0.8 Training
Fire drill exercise will be done periodically to ensure workers are trained in case of emergency.
Basic Occupational First Aid training will be planned and give to the employees there so that
they are well-versed during emergency. Other training necessary such as machinery safety and
PPE is in plan and will be given at appropriate time.

7.0 SUMMARY

No
1

Picture

Findings

Recommendation

Person-in-charge

EDM room, lapping room and To install exhaust fan with high Management
silica carbide room have no velocity or local exhaust ventilation HSSE
exhaust fan to captures the to remove the fumes efficiently
fumes and channel it outside

&

Cable and wires of computer Buy and use cable zip to properly IT Department
at machine is poorly managed tie all the cable together

No label indicating recycle

paper container

Lot of things being stored To clear the area of unnecessary Factory

improperly under the stairs
things

To print and put up label indicating HSSE

recycle paper

No designated area for pallet

truck

To draw safety lines for pallet truck Batu Caves and

parking
HSSE

Metal chips tend to escape to To put up guard or barrier to Batu Caves and
the floor
prevent metal chips from escaping HSSE
to the ground floor

No proper chemical cabinet Buy proper fire resistance cabinet HSSE

for storage of chemical
with spill containment features for
chemical storage

Inadequate
labelling
chemical container

of

To produce a standardized label HSSE

for all chemical container which
meet the requirement

Improper container for

chemical
No label pasted at the
container

To buy proper container for HSSE

chemicals
To put chemical label for the
container

10

Notification is not made to

DOE
Inventory has not been
done for scheduled wastes
No segregation between
general and scheduled
wastes
Inadequate label for
scheduled waste container
No appointer contractor for
scheduled wastes disposal

Notification will be made to Batu Caves and

DOE as in legal requirements
HSSE
To produce monthly inventory
for scheduled waste volume
produced
No
segregation
between
general and scheduled wastes
To produce label as stated in
Scheduled Wastes Regulations
2005 for all scheduled waste
types
To appoint licensed contractor
for collection and disposal of
scheduled wastes

11

Unsuitable types of PPE for

workers usage

For particulate protection, type HSSE

of respirator should be N99
filter
For chemical vapour, type of
respirator is P95

12

No signage to warn about the

elevated barrier

To produce signage and put it at HSSE

place

13

No exit signage at the door

To install exit signage on top of the HSSE

door

8.0 Conclusion
After the audit was done, it is found out that a lot of HSSE issues such as scheduled waste,
chemical management, emergency response plan and trainings can be improved. Safety and
health aspect are very vital in successful business operation and must be given attention as
other critical business decision. This is to ensure safe working environment thus protecting the
safety and health of workers and the environment.