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Company's Name:

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Part-3 Accidents

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PART-2
Members : Divanesvaren, Lingeswarran, Hemalatha, Nazila, Farzana

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Group 15 metal

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PART-1
Members : Divanesvaren, Lingeswarran, Hemalatha, Nazila, Farzana

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Flow chart Group 10
(Oil and Gas)

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Members: Afnan, Muhammad, Qistina,Diana, Amira

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Members: Roshaliza, Ikmal, Poovarasu, Nadiah, Adila Hazwani

Background of Incident:
Name of the company: Hasnon Gold Mine
Date: 15 April 2019
Time: 2.30pm

Chronological of incident:
On the stated day above, we conducted blasting operation in our mine. All the workers were in the plant before the blasting. Unexpectedly, there were flyrocks hit the plant roofing and five workers were injured. The investigation of the incident is carried out.

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Member:
Tan Hui Fang
Lim Shu Sien
Chan Yong Chien
Hazry Hairuddin

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GROUP 20(Oil and gas)
member:sara,ami,dilah,quan yi

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Members: Syafiq Naawin Farhan Kelvin Nazif
Latest Update: 24/09/2019

Background of Incident:
On 9 November 2015, DEF Quarry Sdn. Bhd had an accident at the working site. This is because of the hanging rock at the site after the blasting. The falling rock hit one of the excavator causing the driver injuries and affecting the company daily production

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Members :
Tan Phua Wei
Looi Kah Fung
muhd fauzan bin mohd faisal ettian
Ku Muhd Amir

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Members: Ali Murtadha, Carrie Tie Jia Ling, Cheng Zhe Chian, Chong Wei Ting, Sim See Yi

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Members: Chong Kah Kei, Leong Wei Juang,  Lim Ling Xin, Tan Kai Qi

Silicon Wafer Manufacturing Process

Background of Incident
On 3rd September, ABC Semiconductor company had contamination cases.  From the early morning, the first part of the etched iron ion pollution was transmitted, and later it was the photoresist pollution, and the impact was expanded. When the etched iron ion pollution is transmitted during etching process,  the semiconductor components will be shrinking because the size of the terminal electronic products is getting smaller and smaller. Because the front transistor is contaminated, it may cause abnormal leakage of the wafer, which will cause explosion and affect the yield and reliability of the output degree. This explosion had caused a worker injured.

Process Flow

Investigation
- using fishbone and 5M method

Cause:
The abnormal leakage of wafer caused explosion happened and one worker is injured

Prevention:
Material

1.      Enforcement in the QA checking on the incoming raw material

2.      Scheduled online inspection during the fabrication

3.      Enforce good manufacturing practice

Management

1.      Provide monthly training to all operators and follow up their progress in understanding the SOP through test.

2.      Revised SOP by providing clear flowchart on the machine area.

3.      Provide safety training and proper safety equipment to all workers when they first enter the company.

Man

1.      Implement training of new workers by the experienced workers before going to the production lines

2.      Implement merit-demerit system to all workers

3.      Explain the consequences of disobeying the SOP to the workers to increase the awareness of the safety.

Machine

1.      Arrange yearly maintenance of the machine and internal checking on the machine for every month

2.      Arrange the “machine rest time” to prevent machine damage which may cause accident such as explosion

Method

1.      Revise the Standard Operation Procedure (SOP)

2.      Implement a clear Standard Operation Procedure on the incoming raw materials checking

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Members: Cheang Khai Xian, Chin Kah Boon, Ng Chin Ying, Quek Ser Won

Background of incident

Ali was machine operator who working at an operating station for a hot rolling mill machine. He was a new worker for xxx company for about 2 months. Hot rolling mill is a device meant for pressure shaping of the metals or other materials between the rotating rolls. On 17 September 2019, Ali work as usual in inspecting the working operation of hot roll mill machine. Suddenly, he realised that there was a loosen screw above the hot roll mill machine. He tried to tight the screw. For safety issues, he needs to wear the leather gloves before doing the operation. However, he could not find any leather gloves from the cabinet, but he found plastic gloves. Without hesitating, he proceeded with plastic gloves. He did not stop the operation of hot roll mill while tightening the screw. Suddenly, his hand accidentally stuck inside the hot roll mill and his hand injured.

Cause of incident

wearing wrong safety        precaution equipment

carelessness

Lack of awareness

Management not being committed to health and safety

Lack of supervision and monitoring

Inadequate maintenance

Preventive Action

Know the hazards and dangers in the job to be done

Be aware of hot areas

Be aware of rotating or moving surfaces

Wear the suitable glove during maintenance machine

Product and cost detail in link.

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MEMBERS: syazwani, faqihah, eliza, afaf, siti

ACCIDENT CHRONOLOGY:

A worker from the maintenance department had been attached to the conveyor belt for maintenance duty once for a month. On that month, an accident occurred when he try to repair the one part of the idler of the conveyor belt. The conveyor belt suddenly switched on while he was repairing that part while his hand still working on that part. His index finger was stuck in between the idler and belt. He suffered a permanent scar on his finger.

COST ESTIMATED:

Total cost = Cdirect + Cindirect + Cpayment + Cimmeasurable
=RM 84100

Cdirect = Cdamage + CmedicaL + Cfine + Cinsurance

= RM 13000

Cindirect = Ccapacity lost + Cschedule + Crecruit + Cwork time + Cwip+ Cmang

= RM13100

Cpayment = M(PaynewW1) + ΣBi -  NI x W2

=RM50000

Cimmeasurable = Creputation + Cmorale

= RM8000

CAUSES OF ACCIDENT:

Lack of guards on equipment.

Inadequate or improper training of workers.

Workplace faults that expose workers to conveyor belt hazards.

Incorrect assembly of the conveyor belt.

Inadequate maintenance or inspection of the conveyor belt.

PROCESS FLOW:

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Company name (group11)
Makmun Sdn. Bhd.
Eng Lye Yee
Ngo Jia Yoeng
Tan Jin Zheng
Khairul afif bin Khairulanuar
On 28th June, one engineer in semiconductor factory hurt himself in the sawing process.
In the sawing process, the engineer tried to take the singulated units after drying.
His finger was clamped by the machine parts and fractured.

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Company Name: @BUDAKGETAH
-Vishnu
-Chin Wei Ren
-Syamil
-Firdaus
-Hakimi

Total cost= C direct+ C indirect+ C payment+ C immeasurable
= RM 10 500+ RM 1 600+ RM 43 400+ RM 8 000
= RM 63 500

1. C direct= C medical+ C insurance= RM 10 500

Hospitalization and treatment: approximate RM 10 000
C insurance= RM 500/ Staff (annual)

2. C indirect= C recruit+ C work time = RM 1600
1. C recruit= RM 1200 (foreign worker from third world country, 2 year contract base)
2. C work time= RM 400 (OT 5 days)

3. C immeasureable = C reputatation + C morale = RM8000
Creputation= RM5000/production
C morale = RM3000

4. C payment= (PayNew)+Bi+Ni)W2
C payment= 2(1200+10 500+ 10 000)
= RM 43 400

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Company Name :
JunZiQuanZiqSiew

Background of Accident
Glaze contains silica, fluxes and colorants. Common fluxes include lead. Flooring tiles made with lead glaze are water resistant and cannot be damaged easily. These materials are often in fine powdered form, and result in high dust exposure. Glazes can be dipped, brushed, poured, or sprayed on the tiles. During glazing process, one of the worker was exposed to lead compounds by inhalation and direct skin contact during daily working routine. After 3 years, he was diagnosed lead poisoning.

Total cost= C direct+ C indirect+ C payment+ C immeasurable
= RM 12 500+ RM 1 800+ RM 82 600+ RM 3 000
= RM 99 900

a) C direct= C medical+ C insurance= RM 12 500

Hospitalization and treatment: approximate RM 12 000 in government hospital, KL area, normal treatment

C insurance= RM 500/ Staff (annual)

b) C indirect= C recruit+ C work time = RM 1800
1. C recruit= RM 1300 (foreign worker from third world country, 2 year contract base)
2. C work time= RM 500 (OT 5 days)

c) immeasureable = C reputatation + C morale = RM3000
Creputation= rm0 (no product delays)
C morale = RM3000

d) C payment= (PayNew)+Bi+Ni)W2
C payment= 2(1300+30 000+ 10 000)
= 82 600

Flow Chart of Ceramic Processing

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Company name:: MasBossku Airecraft Sdn Bhd

Flow chart of manufacturing of rotor blade

Issues will be happened:
During lay up process, spraying poisonous chemical will cause health issues. Potential health hazards associated with the use of advanced composites can be controlled through the implementation of an effective industrial hygiene program. Use of safe work practices, engineering controls, and proper personal protective equipment depends upon an appreciation of health hazard information for a safe work environment.

Total cost = Cdirect + Cindirect + Cpayment + Cimmeasurable

The parameters that reflect the direct costs are formulated as

Cdirect = Cdamage +  CmedicaL + Cfine + Cinsurance

10 operator is employed in spraying department. 7 operator is suffered from health problem.

Direct cost = RM 707,000

| Direct cost issues | Amount (single cost) | quantity | Amount  | Review
| Damage cost  | 0 | - | 0 |
| Medical cost + insurance  | 100,000 | 7 | 700,000 |
| Fine cost | - | - | 7,000 |
| Total  |   |   | 707,000 |

Indirect cost = RM 166,480

| Indirect cost issues | Amount (single cost) | Duration  | Amount  | Review
| Capacity lost | 320,000 | 26 |   |
| Schedule lost | 2000 | 50 | 100,000 |
| Recruit cost | 2000 | 5 | 10,000 |
| Work time lost cost | 5 | 208 | 1,040 |
| Wip cost | 255 | 20 | 5,100 |
| Manager cost | 3356 | 15 | 50,340 |
| total |   |   | 166,480 |

Cpayment = (Paynew + ∑Bi + Ni)  x W₂ = RM 2408 × 7 = RM16856

| Payment cost issues | Amount (single cost) | Amount  | Review
| Paynew  | 2000 | 2000 |
| Worker benefits(Bi) | 100 | 100 |
| National insurance refund(Ni) | 100 | 100 |
| Work time lost cost | 208 | 208 |
| total |   | 2408 |

Cimmeasurable = Creputation + Cmorale  = RM 301,000

| immeasurable cost issues | Amount (single cost) | Amount  | Review
| Reputation cost | 300,000 | 300,000 |
| Morale cost | 1,000 | 1,000 |
| Total  |   | 301,000 |

Total cost = Cdirect + Cindirect + Cpayment + Cimmeasurable

= RM707,000 + RM 166,480 + RM16,856 + RM 301,000

= RM 920436.00

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Company name: JoeweenArHanHun

Flow chart of Manufacturing Process of Rubber Mat
As shown in the flow chart below.

Background of the Incident

A mill operator began feeding rubber compound into two roll mill. When adding ingredients into the mill, there are leftover compounding materials on the surface of the mill. The operator tried to remove the ingredients using his hands with gloves on. His glove and hand was caught and trapped in between the rotating mills. Eventually he freed himself by pulling away from the machine causing the de-gloving of both hands This resulted in the medical amputation of both hands.

Cost of the Incident

Total Cost = Cdirect + Cindirect + Cpayment + Cimmeasurable   where,

The parameters that reflect the direct costs are formulated as

Cdirect = Cdamage + Cmedical + Cfine + Cinsurance ;

= RM 300 + RM 15,000 + RM 7,000 + RM 150

= RM 22,450

The parameters which reflect the indirect costs are formulated as

Cindirect = Ccapacity lost + Cschedule + Crecruit + Cwork time + Cwip + Cmang ;

= RM 5,000 + RM 3,000 + RM 1,100 + RM 150 + RM 10,000+ RM 5,000

= RM 24,250

Cpayment = M(PaynewW₁) + Bi - NI x W₂ , and

= RM 100,000

Cimmeasurable = Creputation + Cmorale

= RM 10,000

Hence,

Total Cost = RM 22,450 + RM24,250 + RM 100,000 + RM 10,000

= RM 134,870

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Process :
Accident:

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Process in metal company

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J&K Construction Sdn Bhd
1. Ow Guan Yi
2. Cheng Min Xian
3. Pang Jia Wei
4. Wan Soon Fatt

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Tile Making Industry
1. Samuel Edmund Theivendran
2. Kaveenesh Parameswaran
3. Logarajan Ramasamy
4. Nadia

Total cost = Cdirect + Cindirect + Cpayment + Cimmeasurable

Cdirect = RM 75,000 + RM 5,000+ RM 10,000 = RM 90,000
Cindirect = RM 300,000 + RM 100,000 + RM 2,000 + RM 3,000 = RM 405,000
Cpayment = RM 8,000
Cimmeasurable = RM 50,000
Total Cost = RM 553,000

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Accidents in Grinding Process articles_img01

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Group Members:
1. Akram
2. Catherine Chong Kai Tze (134306)
3. Yeo Ying Hui (134341)
4. Teo Ling Wei (134337)
5. Ang Sheong Yee (134932)

Company:
TaoJin Plastic Sdn. Bhd.

Product: Plastic bag used in supermarket

Process:
1. Mixing department will compound the resins according to the formulation given using mixer.
2. The prepared resin compound will then be stored in a large container which then send to the extrusion line using fork lift.
3. At the extrusion line, the operator will feed the resin compound into the hopper of the extruder machine.
4. After that, the operator will setup the extrusion machine for the blown film extrusion of the film roll.
5. The layflat film will then be winded into a big roll at the winder machine.
6. The film roll then will be transported to the cutting department using fork lift.
7. At the cutting department, the operator will load the film roll onto the machine responsible to cut and heat seal the film roll creating plastic bag as the end product.

Background about the accident:
# Date: 1 September 2019
# Time: 3.00P.M.
# Incident: An Operator cut his fingers at the cutting section

Cost of the Incident

Total Cost = Cdirect + Cindirect + Cpayment + Cimmeasurable   where,

The parameters that reflect the direct costs are formulated as

Cdirect = Cdamage + Cmedical + Cfine + Cinsurance ;

= RM 1,505 + RM 5,000 + RM 15,000 + RM 5,000

= RM 26,505

The parameters which reflect the indirect costs are formulated as

Cindirect = Ccapacity lost + Cschedule + Crecruit + Cwork time + Cwip + Cmang ;

= RM 10,000 + RM 20,000 + RM 500 + RM 200 + RM 5,000+ RM 5,000

= RM 40,700

Cpayment = M(PaynewW₁) + Bi - NI x W₂ , and

= RM 4,100

Cimmeasurable = Creputation + Cmorale

= RM 15,000

Hence,

Total Cost = RM 26,505 + RM40,700 + RM 4,100 + RM 15,000

= RM 86,305