Contents

List of Figures and Tables.................................................................................................................................3

1.0 INTRODUCTION.......................................................................................................................................4
1.1 What is Occupational Safety and Health?................................................................................................4
1.2 Occupational Safety and Health Act (OSHA) 1994.................................................................................4
1.3 Tan Chong Motor Assemblies Sdn Bhd..................................................................................................5
2.0 PART A: DESIGN THE FACILITIES FOR OCCUPATIONAL SAFETY AND HEALTH.....................6
2.1 Designation to Prevent Hazard................................................................................................................6
2.2 Safety Equipment and Personal Protective Equipment............................................................................6
2.3 Maintenance Program..............................................................................................................................7
3.0 PART B: HAZARD ASSESSMENT, PREVENTION AND CONTROL...................................................8
3.1 MECHANICAL HAZARD.....................................................................................................................8
3.2 ELECTRICAL HAZARD.......................................................................................................................9
3.3 ERGONOMIC HAZARD.....................................................................................................................11
4.0 PART C: ACCIDENT INVESTIGATION AND REPORTING...............................................................13
4.1 Incident Simulation...............................................................................................................................14
5.0 PART D: ACCIDENTS AND THEIR EFFECT.................................................................................18
5.1 Cost of Practicing OSH...................................................................................................................18
5.1.1 Helmets........................................................................................................................................18
5.1.2 Cover-all suit...............................................................................................................................19
5.1.3 Safety boots.................................................................................................................................19
5.1.4 Ear-plugs or ear-muffs.................................................................................................................19
5.1.5 Safety goggle...............................................................................................................................20
5.1.6 Safety and Warning Signs............................................................................................................20
5.1.7 Communications devices.............................................................................................................21
5.1.8 Emergency plan routes.................................................................................................................21
5.1.9 Pedestrian and Vehicle Route Separation....................................................................................21
5.1.10 Safety handbook......................................................................................................................22
6.0 PART E: OSH Management System.........................................................................................................27
6.1 Daily and Routine Enforcement............................................................................................................27
6.2 Occupational Safety and Health Policy.................................................................................................27
6.3 Occupational Safety and Health Committee and Emergency Response Team (ERT)............................28
6.4 Notification, Warning & Emergency Preparation Procedure/ System...................................................29
6.5 Awareness and Training Program..........................................................................................................30
6.6 Personal Protection Equipment (PPE)...................................................................................................36
1
REFERENCES................................................................................................................................................39

2
List of Figures and Tables
Figure 1 Personal Protective Equipment............................................................................................................7
Figure 2 Hierarchy of control measures............................................................................................................8
Figure 3 Cut Simulator......................................................................................................................................9
Figure 4 Electric shock due to control button does not completely switch off.................................................10
Figure 5 Using Damaged Tools.......................................................................................................................10
Figure 6 Trolley Handling...............................................................................................................................11
Figure 7 Hazard sign in factory.......................................................................................................................12
Figure 8: Stop Work Order (SWO) Penalty.....................................................................................................13
Figure 9: Accidents Penalty.............................................................................................................................13
Figure 10: Evacuation Procedure.....................................................................................................................15
Figure 11: Sign of Falling Objects From Top..................................................................................................16
Figure 12: Dengue...........................................................................................................................................17
Figure 13 Helmet being used in Tan Chong Motor..........................................................................................18
Figure 14 Cover-all suit for employee..............................................................................................................19
Figure 15 Safety google in Tan Chong Motor Assemblies Sdn Bhd..................................................................20
Figure 16 Safety and warning signs in Tan Chong Motor Assemblies Sdn Bhd................................................20
Figure 17 Route separations and metal gates in Tan Chong Motor Assemblies Sdn Bhd................................21
Figure 18 Safety handbook..............................................................................................................................22
Figure 19 Medical check-up for employees in Tan Chong Motor Assemblies Sdn Bhd...................................22
Figure 20 Palleted truck and forklift in Tan Chong Motor Assemblies Sdn Bhd.............................................23
Figure 21 Lost Time Injury Rate (LTIR).........................................................................................................27
Figure 22 Map of the emergency gathering place............................................................................................29
Figure 23 Evacuation procedure that is placed around the plant......................................................................29
Figure 24 Evacuation procedure of the plant...................................................................................................30
Figure 25 TCMA’s women firefighters in action during fire drill...................................................................30
Figure 26 Firefighting training........................................................................................................................31
Figure 27 Forklift operation training...............................................................................................................31
Figure 28 PPE training- hearing protection.....................................................................................................32
Figure 29 Breast Cancer Awareness campaign................................................................................................32
Figure 30 Bone density check.........................................................................................................................33
Figure 31 World Health Day participants........................................................................................................33
Figure 32 Blood pressure check......................................................................................................................33
Figure 33 Some of the training that is provided in the training centre.............................................................34
Figure 34 Training how to switch on, off and emergency button....................................................................34
Figure 35 Road Crossing Guideline.................................................................................................................35
Figure 36 Caught Simulator (Drill).................................................................................................................35
Figure 37 Safety Shoes Simulator (Fall)..........................................................................................................36
Figure 38 PPE provided by the company for the workers...............................................................................36

Table 1 Cost of Practising Occupational Safety and Health in Tan Chong Motor Assemblies Sdn Bhd For A
Year................................................................................................................................................................. 25
Table 2 Cost of Non-Practising Occupational Safety and Health in Tan Chong Motor Assemblies Sdn Bhd For
A Year..............................................................................................................................................................26
Table 3 Lost Time Injury Rate (LTIR)............................................................................................................28

3
4
1.0 INTRODUCTION

1.1 What is Occupational Safety and Health?

Occupational safety and health (OSH), also commonly referred to as occupational health and safety
(OHS), occupational health, or workplace health and safety (WHS), is a multidisciplinary field
concerned with the safety, health, and welfare of people at work. These terms of course also refer to
the goals of this field, so their use in the sense of this article was originally an abbreviation of
occupational safety and health program/department etc.

The goals of occupational safety and health programs include to foster a safe and healthy work
environment. OSH may also protect co-workers, family members, employers, customers, and many
others who might be affected by the workplace environment. In the United States, the term
occupational health and safety is referred to as occupational health and occupational and non-
occupational safety and includes safety for activities outside of work.

In common-law jurisdictions, employers have a common law duty to take reasonable care of the
safety of their employees. Statute law may in addition impose other general duties, introduce
specific duties, and create government bodies with powers to regulate workplace safety issues:
details of this vary from jurisdiction to jurisdiction. All organizations have the duty to ensure that
employees and any other person who may be affected by the organization's activities remain safe at
all times.

1.2 Occupational Safety and Health Act (OSHA) 1994

OSHA 1994 is a piece of Malaysian legislation which was gazetted on 25 February 1994 by
Malaysian Parliament, The purpose of this act is to:

1 Securing the safety, health and welfare of person at work.

2 Protect person at work other than employees
3 Promote a suitable environment for person at work
4 To Enable previous legislation to be replaced by regulations and approved industry codes of
practice operating in combination with the OSH Act 1994
The regulations under OSHA 1994 are:
5
 1 OSH (Employers’ Safety and Health General Policy Statement) (Exception) Regulations
1995
2 OSH (Control of Industrial Major Accident Hazards) Regulation 1996
3 OSH (Classification, Packaging and Labelling of Hazardous Chemicals) Regulation 1997
4 OSH (Safety and Health Oficer) Regulations 1997
5 OSH (Safety and Health Oficer) Order 1997
6 OSH Prohibition of Used substance) Order 1999
7 OSH (Use and Standards of Exposure of Chemical Hazardous to Health) Regulation 2000
8 OSH (Indoor Air Quality) Code of Practice 2005

1.3 Tan Chong Motor Assemblies Sdn Bhd

Located at Mukim Serendah, Rawang, Tan Chong Motor Assemblies Sdn. Bhd is a car assembling
plant. Specialise in assembling the brand new Nissan car, the plant has many heavy machinery and
workers, from the top level management until the machine operator. Based on the site visit, we
could see that the plant is following the occupational safety and health act. The plant is also have
many safety features which will be discussed later. The purpose of the visit is to learn the working
environment of the plant itself as well as to study how the plant asses the hazard present and risk
assessment and take care of the welfare of its worker.

6
2.0 PART A: DESIGN THE FACILITIES FOR OCCUPATIONAL SAFETY
AND HEALTH

2.1 Designation to Prevent Hazard

The plant itself is already locating itself away from housing areas so that the noise and the lorry used
for logistic purposes does not endangering other people. Due to the foreign workers, the language
barrier makes it very difficult to communicate with them. Thus giving them talk about safety is
meaningless. Therefore the management team especially the safety department team need to give
training and clear effect on the safety and what will happen if not following the safety rules.

Designing of the plant also considered the safety of the workers and other people such as visitors
and maintenance personnel etc. The spacing of the machine and long production with a U-turn really
increase the safety to them.

During our visit, we were reminded to wear the safety boots and safety jacket. Upon arriving at the
plant we were given an inspection in order to see if we were wearing protective shoes. Also a
briefing and a safety helmet.

2.2 Safety Equipment and Personal Protective Equipment

During our visit there, we were given a briefing and a safety helmet. At this plant the personal
protective equipment are as shown in figure below.

7
 Figure 1 Personal Protective Equipment

2.3 Maintenance Program

The maintenance is scheduled and it is put up at the entry of the plant. The maintenance is scheduled
every 3 months and the company that produce the machine will send their technician to the plant.
Every maintenance is recorded on the maintenance board.

8
3.0 PART B: HAZARD ASSESSMENT, PREVENTION AND CONTROL
HAZARDS

Hazard is any biological, chemical, mechanical, environment or physical agent which

potential damage, harm or adverse health effects on something or someone under certain conditions
at work. Factory like Tan Chong Assemblies Sdn Bhd always practicing safety policies to prevent
the hazard occur in the company. Every each of their workers in the company were being trained
and exposed every year about the hazard in the workplace and also learn about the precaution if
anything bad happen in the factory.

Effective controls protect workers from workplace hazards and it helps avoid injuries,
illnesses, incidents, minimize or eliminate safety and health risks and also help employers provide
workers with safe and healthful working conditions. A simple control measure can be done if the
secure guarding of moving parts of machinery eliminating the potential for contact which is when
we look at control measure we often refers to the hierarchy of control measures. Tan Chong
Assemblies Sdn Bhd staffs are so discipline and obey the rules in hierarchy of control measures.

Figure 2 Hierarchy of control measures

3.1 MECHANICAL HAZARD

Mechanical hazards are created as a result of either powered or manual (human) use of tools,
equipment or machinery and plant. An example of a mechanical hazard is contact or entanglement
with unguarded moving parts on a machine. Mechanical hazard always occur dangerously in Tan
Chong Assemblies Sdn Bhd are the moving parts areas which require safeguarding. The basic area
that require safe guarding are:
9
  The point of operation: that point where work is performed on the material, such as cutting
box and transferring panel parts.
 Power transmission apparatus: all components of the mechanical system that transmit
energy to the part of the machine performing the work. These components include flywheels,
pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks, and gears.
 Other moving parts: all parts of the machine that move while the machine is working.
These may include reciprocating, rotating, and transverse moving parts, as well as feed
mechanisms and auxiliary parts of the machine.

In order to properly protect workers, safeguards should prevent contact which prevent worker’s
body or clothing from contacting hazardous moving parts and be secure to machine and not easily
removed. Other that, to protect workers from falling objects, the workers should ensure that no
objects can fall into moving parts and wear the safety helmet provided by the company. The
supervisor should create no interference which they must not prevent workers from performing the
job quickly and comfortably.

Figure 3 Cut Simulator

Cause Accident: Workers negligence as he did not wear proper glove while handling a knife.
Countermeasures: Supervisor have to arrange to change cotton glove to Kevlar gloves.

3.2 ELECTRICAL HAZARD

An electrical hazard is a dangerous condition where a worker can or does make electrical
contact with energized equipment or a conductor.  From that contact, the person may sustain an
injury from shock, and there is a potential for the worker to receive an arc flash burn, thermal burn
or blast injury. Electricity can either be "static" or "dynamic".  Dynamic electricity is the uniform
motion of electrons through condition (electric current).  Static electricity is the accumulation of
charge on surfaces as a result of contact and friction with another surface.

10
 Common tasks that put these workers at risk include electrical installation and repairs,
testing of fixtures and equipment and inspection and maintenance activities. Electrocution is one of
the most common hazards across construction sites according to OSHA. Identifying electrical
hazards can help raise awareness of the risks, their severity, and how it can harm workers. The
problem that occur at Tan Chong Assemblies Sdn Bhd are electric shock, using damaged tools and
equipment and wet conditions.

Figure 4 Electric shock due to control button does not completely switch off

Figure 5 Using Damaged Tools

In order to prevent these hazards, a few preventions have been made:

i. The equipment that damaged need to have them repaired or replaced. Lock Out Tag
Out (LOTO) procedures performed at all times before commencing electrical
maintenance and repairs. LOTO procedures are there to protect all workers on a
worksite.
11
 ii. Examples of exposed electrical parts include temporary lighting, open power
distribution units, and detached insulation parts on electrical cords. These hazards can
cause potential shocks and burns. Secure these items with proper guarding
mechanisms and always check for any exposed parts to be repaired immediately.
iii. The workers need to alert that never operate electrical equipment in wet locations.
Water greatly increases the risk of electrocution especially if the equipment has
damaged insulation. Have a qualified electrician inspect electrical equipment that has
gotten wet before energizing it.

3.3 ERGONOMIC HAZARD

An ergonomic hazard is a physical factor within the environment that harms the
musculoskeletal system. Ergonomic hazards include themes such as repetitive movement, manual
handling, workplace, uncomfortable workstation height and poor body positioning. Ergonomics is
the study of how a workplace, the equipment used there and the work environment itself can best be
designed for comfort, efficiency, safety and productivity. Often we can improve our levels of
comfort and productivity with relatively simple changes.

The possible hazard that can occur at Tan Chong Assemblies Sdn Bhd are uncomfortable
workstation and poor manual handling when lift up the bid product.

Figure 6 Trolley Handling

In order to prevent these hazards, a few preventions have been made:

i. Use a device to lift and reposition heavy objects to limit force exertion.
ii. Reduce the weight of a load to limit force exertion.
12
iii. Reposition a work table to eliminate a long/excessive reach and enable working in
neutral postures.
iv. Use diverging conveyors off a main line so that tasks are less repetitive.

Figure 7 Hazard sign in factory

13
4.0 PART C: ACCIDENT INVESTIGATION AND REPORTING
An accident is an unplanned, unforeseen and unexpected event that has a negative effect on
all activities of the individual or group that involved. It can result in fatal, injury, disease or
infection, damage to environment or loss of property. In Occupational Safety and Health (OSHA)
there is always a priority to the worker to keep their safety and aware of the hazards, so any
accidents can be prevented.

At Tan Chong Motor Assemblies Sdn. Bhd. workplaces, if any accidents that happen or any
worker that did not use the safety equipment and unsafe behaviour, the SH Department will request
Stop Work Order (SWO).

Figure 8: Stop Work Order (SWO) Penalty

Figure 9: Accidents Penalty

14
4.1 Incident Simulation

Case 1: Fire

Fire is the higher potential accidents which can be occur because this company have many
causes that may lead to fire. Since Tan Chong Motor Assemblies Sdn. Bhd. mostly using the
machine to assemble parts, so it will use more electric current supply. If short circuit happened, it
will cause fire. The followings are the procedure needs to be taken when fire happen:

1. Alarm will be sound, and drill will be ringing.

2. Represented personnel/supervisor/ leader inform to security immediately.
3. Receptionist announce to all workers to evacuate safely from location of fire. Fire squad and
first aid team assist workers to leave the building immediately to the assembly point.
4. Check attendance and report missing person to incident controller.
5. Early treatment to injured person need to perform by first aid team.
6. Security identifies zone location of fire alarm and report to the fire squad or SHO. Security
confirm with BOMBA through CMS telephone.
7. Determine can/ can’t fight fire with available equipment. If SHO/ incident controller/ fire
squad can take the action by using fire extinguisher unless uncontrollable fires situation, just
wait for BOMBA rescue.
8. Developed prevention measure and record.

15
Figure 10: Evacuation Procedure

16
Case 2: Falls from high heights

At the Tan Chong Motor Assemblies Sdn. Bhd. workplace, there are machine that operate in
high place to assemble parts. If there is an accident that happening there, and the worker is seriously
injured and need a treatment at hospital. During that time, these are the procedures that should be
taken:

1. Inform the site supervisor immediately.

2. Site supervisor sounds the emergency alarm and quickly evaluates the situation and
identifies any further hazards that could arise.
3. Emergency Rescue Team conducts Emergency Rescue Plan
4. Call and notify local police, Bomba, and/or ambulance if required.
5. Isolate the accident zone and move all non-affected personnel to a safe zone.

Case 3: Falling debris, materials or objects

During working at assembly workplace, object fall from top may occur. Therefore, worker will be
provided with safety helmet. But when an accident happened, these procedures need to be followed:

1. Contact the nearest First Aid Officer within the building.

2. Send the injured person to nearest medical centre if necessary (business hours only).

3. Inform supervisor.

4. Complete a confidential incident/injury report.

Figure 11: Sign of Falling Objects From Top

17
Case 4: Vehicle

The trolley were used to deliver the parts between building. The incident may occur if the bumper
racking that is push by other workers hit the others.When there are people that get hit by the racks,
these following are the step needed to follow:

1. Stop the trolley at safe place to prevent other accident.

2. Check the injury of the worker.
3. Call the supervisor
4. Sound the alarm to stop the working and start to rescue the victim.
5. Call police or ambulance to bring the victims to hospital

Case 5: Dengue

At the construction site, there are many places that can be the place for Aedes mosquitoes to breed.
The most place are plastics. Plastic that contain water will attract Aedes mosquitoes to go there and
laying eggs. When someone diagnose with Dengue:

1. The site will be closed, and all the operation will be stop.
2. KKM will conducted checks at sites where it found Aedes breeding grounds and high
mosquito population.
3. The department then took steps to control and prevent the disease from spreading including
fogging, destroying Aedes breeding grounds and held a gotong-royong to
4. Clean up the affected areas

Figure 12: Dengue

18
5.1 PART D: ACCIDENTS AND THEIR EFFECT
5.2 Cost of Practicing OSH
Tan Chong Motor Assemblies Sdn Bhd is practicing the best occupational safety and health
(OSH) in workplace. The facility equipped with adequate safety measure equipment such as
personal protective equipment, safety warnings and signs, route for pedestrian is separated
from vehicle route, communication devices and safety handbook for all workers. The facility
also in compliance with UBBL 1984, equipped with enough fire prevention such as
emergency route plan, exit signs, fire extinguisher, fire alarms and fire hydrants.

Total costs for facilities are includes personal protective equipment from head to toes,
communication devices, safety arrangement between employees and vehicles such as forklifts
and pallet trucks is approximately RM 92,670. Cost for PPE as follows:

5.2.1 Helmets
Helmet provided in Tan Chong Motor Assemblies Sdn Bhd approved by SIRIM and qualified
to be used in industry deals with electrical sources. Tan Chong Motor Assemblies Sdn Bhd
provides safety helmets for all employees including managing director, which are 175 in
total. Cost for each safety helmet is RM 78, the overall total for helmet only is RM 13,650.
Many more helmets may be provided to replace the broken safety helmets throughout the
year.

Figure 13 Helmet being used in Tan Chong Motor

Figure _

19
5.2.2 Cover-all suit
Safety jacket used in Tan Chong Motor Assemblies Sdn Bhd is a cover-all suit type with light
reflector, cost for each suit ranging from RM 120- RM 450, but the one that being use in Tan
Chong Motor Assemblies Sdn Bhd cost RM 165. Consider for 175 people, the total cost for
cover-all suits is about RM 28,875.

Figure 14 Cover-all suit for employee

Figure _

5.2.3 Safety boots

Before doing jobs in Tan Chong Motor Assemblies Sdn Bhd, all employees are required to
wear safety boots as a safety precaution. In Tan Chong Motor Assemblies Sdn Bhd, safety
boots for new worker is provided and the cost for each safety boot is RM 50. To sum up the
total cost for safety boots in Tan Chong Motor Assemblies Sdn Bhd only is RM 8,750.

5.2.4 Ear-plugs or ear-muffs

Manufacturing processes in Tan Chong Motor Assemblies Sdn Bhd emit a loud noise from
machines that being used to manufacture electrical products. Safety earmuffs are provided by
the company to protect their employees from excessive noise. Cost for each earmuff is RM
30, total cost for 175 peoples is RM 5,250.

20
5.2.5 Safety goggle

Some of the manufacturing process in Tan Chong Motor Assemblies Sdn Bhd requires
employees to wear safety goggles to protect their eyes from hazards. The company takes
initiative to provide safety goggles for all employees, cost for each safety goggle is RM 4
only, and for total cost is RM 700.

Figure 15 Safety google in Figure

Tan Chong
_ Motor Assemblies Sdn
Bhd

5.2.6 Safety and Warning Signs

Safety and warning sign that be installed in Tan Chong Motor Assemblies Sdn Bhd are to
keep reminds the employees about the safety procedures in Tan Chong Motor Assemblies
Sdn Bhd and to take care of themselves and others. About 20 signs installed in this company
and each cost about RM 40, sum-up about RM 800.

Figure 16 Safety and warning signs in Tan Chong Motor Assemblies Sdn Bhd
Figure _

21
5.2.7 Communications devices
Communications device used in Tan Chong Motor Assemblies Sdn Bhd are satellite mobile
phones and walkie-talkies. This type of communications allowing the head of department to
communicate with each other, relying messages across the company. Tan Chong Motor
Assemblies Sdn Bhd provides 6 satellite mobile phones cost RM 3,000 each and 30 walkie-
talkies cost RM 130 each, total for communications devices is RM 21,900.

5.2.8 Emergency plan routes

To smooth the evacuation during emergency, Tan Chong Motor Assemblies Sdn Bhd
provides about 12 emergency plan routes all across the company with total cost of RM 120.

5.2.9 Pedestrian and Vehicle Route Separation

To ensure the safety of employee who walks around the company, they separate the route
between pedestrians and vehicle. Pedestrian routes paint in red color meanwhile vehicles
route green in color. Tan Chong Motor Assemblies Sdn Bhd also installed a metal gates to
enter several areas, this to ensure the safety of people in that area from vehicle hazards. Zebra
crossing also can be found in road connecting two areas. The total cost for implement this
separation routes is about RM 10,000.

Figure 17 Route separations and metal gates in Tan Chong Motor Assemblies Sdn Bhd

22
5.2.10 Safety handbook

Safety handbook provided by Tan Chong Motor Assemblies Sdn Bhd for all employees in
that company, this safety handbook contains all safety precaution by Tan Chong Motor
Assemblies Sdn Bhd itself. Total cost for safety handbook is RM 2,625.

Figure 18 Safety handbook

Tan Chong Motor Assemblies Sdn Bhd also provide a training for new recruit, drivers
for forklift and palette trucks, training for contractors and several seminars. Other than that,
the company also held a safety meeting and monthly assembly on first week each month. An
annual medical check-up for workers are available in Tan Chong Motor Assemblies Sdn Bhd.
Tan Chong Motor Assemblies Sdn Bhd also practising ISO 9001: 2008 that specifies
requirements for a quality management system and ISO 14001: 2004 for an environmental
management system.

23
 Figure 20 Palleted truck and forklift in Tan Chong Motor Assemblies Sdn Bhd

For maintenance cost, Tan Chong Motor Assemblies Sdn Bhd spends about RM
29,000.00 a year on repairing machines, repairing forklifts and palette trucks, insurance and
audiometry test. This cost can be varying each year’s depending on breakdown and
preventive maintenance.

In result for non-practicing OSH, the company might be spending a lot to bring back
the productivity of the company. The greatest cost contributing to company loss will be the
downtime cost as it will be calculated on how much the company will loss every hour the
production not in run. And if there is an accident whether minor or major, the company will
be spending a lot on compensation and medical expenses including medical cost, medical
equipment, rehab and medication cost. In addition, cost for repairing the machines also
included in cost non-practicing OSH.

Both figures below show the cost for practicing OSH and non-practicing OSH. These
costs are calculated based on total 175 workers within a year. There are several costs not
included and not applicable as it is a company privacies.

24
 COST AMOUNT
FACILITIES
Personal Protective Equipment
Helmet 78 175
Cover-all Suit 165 175
Safety Boots 50 175
Ear-plug 30 175
Safety Goggle 4 175
Safety and Warning Signs 40 20
Communication Devices
Satellite Mobile Phone 3000 6
Walkie Talkie 130 30
Emergency Plan Route 10 12
Pedestrian and Vehicle Route Separation 10000 1
Safety and Health Guideline Book 15 175
TOTAL 92,670.00
TRAINING
Emergency Drills
Fire Drill FREE 2
Internal Drill FREE 2
Monthly Assembly FREE 12
Medical Checkup 50 137
Safety Training 2800 2
Road Safety Seminar 3500 1
Training Centre from Japan N/A 1
Forklift and Pallette Truck Training 5000 1
Safety Meeting 1000 12
TOTAL 32,950.00
QUALIFICATION
ISO 9001: 2008 5000
ISO 14001:2004 N/A
TOTAL 5,000.00
MAINTENANCE AND INSURANCE
Machines 10000 Lump-sum
Forklift 9000 Lump-sum
Pallete Truck 9000 Lump-sum
Insurance N/A
Audiometry Test 1000
TOTAL 29000
GRAND TOTAL 159,620.00
Table 1 Cost of Practising Occupational Safety and Health in Tan Chong Motor Assemblies Sdn Bhd For A
Year

25
 COST AMOUNT
DOWNTIME
Productivity (Machines, Worker and Damage) 3200 200 hour/year
REPAIR
Machine 5000 Lump-Sump
LEGAL EXPENDITURE
Medical 7000 Lump-sum
Equipment 5000 Lump-sum
Medication 2000 Lump-sum
Rehab 700 Lump-sum
RECTIFICATION 6000
N/A
COMPENSATION
GRAND TOTAL 665,700.00
Table 2 Cost of Non-Practising Occupational Safety and Health in Tan Chong Motor Assemblies Sdn
Bhd For A Year

From both figures, the total cost for practising OSH in Tan Chong Motor Assemblies Sdn Bhd is RM
159,620.00 approximately and the cost for non-practicing OSH is about RM 665,700.00. From this
value, the difference in cost is about RM 506,080.00, three times the cost for practicing OSH. In
conclusion, practicing OSH in company improves workers’ productivity, reduces compensation
payments due to injuries and reduces rectification cost to do correction after an accident. Also, it will
improve the company reputations that can improve sales and generates more leads to profit.

26
6.0 PART E: OSH Management System

6.1 Daily and Routine Enforcement

1. Job observation

This observation is done daily by the executive engineers and supervisors. The observation is made
departmental. The scope observation is 5S, Unsafe Condition and Quality Production Process.

2. Yellow card

This enforcement is done weekly by plant management and department heads. It consists of plant wide
and the scope enforcement is 5S, Unsafe Conditions and Quality.

3. EHS

There is specific inspection made in the plant. Usually the inspection is made by 2 nd party which is
party from outside the company. They inspect facilities in the plant like forklift, EzGo and canteen.
This is to ensure the facilities are in good shape and safe to be used by the workers.

Besides, there is also general inspection made by them. The inspection includes Unsafe Act, Unsafe
Condition and PPE.

6.2 Occupational Safety and Health Policy

Over the years, the assembly plants have put in various efforts to attain the highest level of safety and
health awareness among its employees, with the aim to be a leading workplace with best care for our
employees’ safety, health and welfare. This is well represented by the decrease in the Lost Time Injury
Rate (LTIR). TCMA continually aims to achieve Zero Accident.

Figure 21 Lost Time Injury Rate (LTIR)

27
 Table 3 Lost Time Injury Rate (LTIR)

There are some policies that are enforced in the company. All the policies are to ensure the safety of
the worker will always guarantee.

Both the management and the staff will work together in preventing any potential non-conformity of
products and services, and any possibility of injury arising from incidents occurring at work places.

This company is committed to:

 Providing and maintaining a quality, safe and healthy work place and system free of any
hazard and risk;
 Ensuring all staff receive relevant information, directives, trainings and supervision on how to
carry out tasks in a correct and quality manner that poses no risks to health;
 Investigating all non-conformities of products and services, incidents, occupational diseases,
occupational poisoning and dangerous events, and taking steps to ensure they are not repeated;
 Identifying and complying with customer requirements, and legal and other requirements as
stipulated in the Occupational Safety and Health Act 1994, its regulations and the approved industrial
codes of practice;and
 Promoting and achieving the objectives of occupational safety and health quality, work
procedures, and rules and guidelines of occupational safety and health among workers across the
country.

6.3 Occupational Safety and Health Committee and Emergency Response Team
(ERT)
In addition, the Group has also embarked on strategies to enhance the Emergency Response by
exposing the ERT members to various trainings such as firefighting, chemical spill handling, first aid,
cardio pulmonary resuscitation (CPR) and so forth at both plants and also its headquarters.

TCMA Serendah’s women’s firefighting team at the plant emerged silver medallist in the annual
Kawad Hos competition for the Hulu Selangor region held at the Kuala Kubu Bharu Firestation. The
Kuala Kubu Bharu Firestation organises the Kawad Hos competition among factories and institutions
in the Hulu Selangor District annually to foster closer ties between the entities and the Fire
Department; in addition to developing highly efficient and effective ERT to mitigate fires and related
injuries. TCMA participated in this competition and emerged silver medallist in the women’s team
category.

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6.4 Notification, Warning & Emergency Preparation Procedure/ System
The company is complete with the procedures preparation for notification, warning and emergency.
All the procedures are put around the plan so everybody either workers or visitors know what to do
when something bad happen.

Figure 22 Map of the emergency gathering place

Figure 23 Evacuation procedure that is placed around the plant

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 2. Be calm and 3. Leave the
1. Operate nearest
stop what you are building by nearest
fire alarm call point
doing emergency exit

5. Do not return to 4. Report to your

the building until assembly point
autorised to do so soon

Figure 24 Evacuation procedure of the plant

6.5 Awareness and Training Program

1. Fire Drill

The Group understands the importance of a well-thought out fire evacuation plan and also the
importance of having a well-prepared Emergency Response Team (ERT) should a fire break out in
any one of its facilities or workplace. To enhance the preparedness of employees in responding to a
fire emergency, fire drills have been organised at different workplaces to create awareness of fire
safety amongst the employees of the Group. The assigned ERT is given a chance to implement their
individual roles in the event of a fire. After each drill, a post mortem is carried out on how to further
improve the evacuation process and emergency equipment for each workplace.

Figure 25 TCMA’s women firefighters in action during fire drill

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 Figure 26 Firefighting training

2. Road Safety

With the current increase of road accidents pertaining to both work-related and commuting to and
from work, the plants have jointly collaborated with Jabatan Keselamatan Jalan Raya (JKJR) to
implement and organise road safety campaigns at several TCMH workplaces to increase the awareness
on road safety for employees in hope to reduce road accidents. JKJR shared information pertaining to
road accident statistic records, as well as preventive actions for road accidents.

Figure 27 Forklift operation training

3. Others Trainings

As the Group is committed to providing a safe and healthy work environment for its employees,
various trainings such as Notification of Accident, Dangerous Occurrences, Occupational Poisoning
and Occupational Disease (NADOOPOD) Training; Hazard Identification and Risk Assessment and
Risk Control (HIRARC); Electronic Scheduled Waste Information System (E-SWIS) are also
constantly being conducted at its headquarters to develop and upgrade the skills and knowledge of
employees.

Demonstrations on safe methods of handling daily tasks were carried out; for instance, forklift
operation training for warehouse employees who are involved with lifting tasks. Other trainings such
as Firefighting, First Aid, Ergonomic, Personal Protective Equipment (PPE) and Chemical Safety were
also conducted to further impart and enhance their knowledge on the proper way to safely carry out
their daily tasks. These trainings have enabled employees to have better understanding and knowledge
of legal compliance in order to create a safer, healthier and environmental-friendly workplace.
Frequencies of these trainings are dependent on the requirement itself.

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 Figure 28 PPE training- hearing protection

4. Medical Screenings

The Group conducted Periodic Medical Screening for its employees in the southern and northern
regions including East Malaysia throughout the year. The primary purpose for this programme is to
assist and encourage employees in adopting and maintaining a healthy lifestyle to improve their well-
being.

5. Pink October

In celebration of Breast Cancer Awareness month, the Group’s Medical Services team held a month-
long campaign and taught Breast Self-Examination (BSE) to all female employees. With an increase
in breast cancer statistics amongst women in the country, prevention is always better than cure and
early detection can lead to a better prognosis.

Figure 29 Breast Cancer Awareness campaign

6. Health Campaigns

Health talk such as Gut Care, Bone Check, How Workplace Ergonomics Causes Neck and Back Pain,
Nutrition and Cholesterol, World Heart Day and Cancer Awareness were carried out periodically in
the year for the employees. We work with retailers and pharmaceutical companies to organise some of
our campaigns.

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 Figure 30 Bone density check

7. World Health Day

During the annual World Health Day, basic medical screening was conducted for all employees at the
Group’s headquarters. In addition to checking blood sugar, cholesterol and blood pressure,
Electrocardiogram (ECG) tests were performed on employees above 40 years of age and those below
40 who have indications for the need of an ECG. Interpretation and report were finalised by our
designated panel doctor.

Figure 31 World Health Day participants

8. Blood Donation Campaign

The Group believes in doing its part to save lives by organising blood donation programmes
throughout the year to support the National Blood Bank. The programmes received good response
from the employees; indicating their concern and support for social needs.

Figure 32 Blood pressure check

9. Safety Awareness Training Centre

The company is also provided a safety awareness training centre. The training centre is used to give
training to the new and old workers about the safety and steps to install PPE.

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Figure 33 Some of the training that is provided in the training centre

Figure 34 Training how to switch on, off and emergency button.

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Figure 35 Road Crossing Guideline

Figure 36 Caught Simulator (Drill)

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 Figure 37 Safety Shoes Simulator (Fall)

6.6 Personal Protection Equipment (PPE)

There are many PPE provided by the company for the safety of the workers. All the PPE have
different uses, based on the function and condition of the working place.

Figure 38 PPE provided by the company for the workers

There are four main plants in the company. The plants are body shop, paint shop, assembly shop and
logistic. Each plant has specific PPE and all workers must wear them on working hours.

36
1. Body shop
 Protective Glasses, Goggles, or Other Eyewear for flying sparks, particles, and molten
metal
 Puncture-Resistant Shoes for falling or rolling heavy objects or in case of exposed
sharp equipment
 Rubber-Lined Shirts, Pants, Gloves, Shoes and other equipment to prevent electric
shock
 Helmets in case of falling objects or impact to the head
2. Paint shop
 Gloves: Always wear gloves to protect your hands. Leather or cloth gloves are
sufficient for sanding. Solvent-resistant gloves are required for handling paint thinner
and other solvents. Impermeable gloves are best for water- and oil-based paint.
 Eye wear: Use protective eye glasses, eye goggles or a face shield whenever handling
paint or paint thinners. It is especially important when painting above their head or
spray painting, as well as when sanding.
 Paint masks: Wear a dust mask or particulate respirator when sanding. If they are
very sensitive to chemicals, they should also wear a respiratory mask when using a
brush or roller. Note that if they are painting outside in an area with lots of birds, they
may need to wear a mask to protect themself from the harmful pathogens in bird
droppings. When they are spray painting, they are best advised to use a paint
respirator, as this offers more protection for their airways.
 Coveralls and shoe covers: A disposable or cotton coverall and disposable shoe
covers serve to protect both their clothing and any exposed skin that could become
irritated by contact with paint.
 Hard hat: If the workers are working at heights, a hard hat is a wise safety
precaution, as it can help protect those head if you fall. Additionally, if they are
working on a busy construction site, it will protect their head if an object falls on
them.
 Fall arrest: A fall arrest system can consist of a single carabiner or double carabiner
that can be attached to a railing to prevent the workers from falling. It often comes
with a harness that straps around the torso and legs for added safety. Scaffolding may
also be used in some situations to prevent injuries from falls.
 Fire extinguisher: It is always important to keep a fire extinguisher on site in case
there are any incidents with flammable materials such as paint thinner.
3. Assembly shop
 Hard hat: Work stations or traffic routes located under catwalks or conveyor belts,
construction, trenching, utility work, etc.

37
  Hearing protection: Disposable, reusable, or headphone types of earplugs
 Protective clothing: Cutting, grinding, sanding, sawing, glazing, material handling,
etc.
4. Logistic shop
 Safety boot: for falling or rolling heavy objects or in case of exposed sharp equipment
 Power rigger gloves: to prevent electric shock
 Jacket
 Work trousers

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 REFERENCES
[Interview With H. J. Kumar]. (n.d.). Tan Chong Motor Assemblied Sdn Bhd.

Occupational Safety and Health Act 1994. (n.d.). Retrieved June 17, 2019, from

http://www.dosh.gov.my/index.php/en/legislation/regulations-1/osha-1994-act-154

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