Executive Summary Report

INTERNATIONAL GENERAL
CERTIFICATE Candidate report template

(2011 specification)
UNIT IGC3 THE HEALTH AND

SAFETY PRACTICAL APPLICATION Sheet No 01 of 08
Location: Interwood Mobel (Pvt) limited Lahore, Pakistan. Student number: 0000000
Date of Review: 16/Septemeber/2012.

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1-Introduction including overview of area inspected and activities taking place:
This report gives you brief description of good & bad/poor practices observed on 16th of
September,2012 relating to health & safety in BOARD SETION (important production area that deals
with artificial wood application) of Interwood Mobel (Pvt) limited, situated in Lahore, Pakistan.
Actually, Interwood Mobel (pvt) limited (leading woodworking industry in country) comprises of
three main production/manufacturing units
1-Unit 01 (Special projects workshop)
2-Unit 02 (Metal working & Powder Coating work shop) for Metallic furniture
3-Unit 03 (Board Section, Wood section, Polish, Upholstery, Assembly Area, Warehouse &
administrative Offices)
1.1-Floor Lay out Plan of Board Section



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1-Introduction including overview of area inspected and activities taking place:
1.2-Process Layout Plan in Board section
Process flows in Board Section
Process Flow 1 (veneer pressed C.B)
Beam Saw Lipping Section Calibration Veneer Press Section Triming Sanding
PVC Lipping Manual lipping Wood lipping
Process flow 2 (Formica + veneer sheets pressing)
Press Beam Saw PVC Lipping CNC
Process flow 3 (Laminated chip board)
Beam Saw PVC Lipping CNC
Process flow 4 (Veneer pressed C.B) with CNC Working

Triming
Beam Saw Lipping Section Calibration Veneer Press Section CNC Sanding
PVC Lipping Manual lipping Wood lipping



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2-Executive Summary:
This report focuses on four major areas where significant improvements are required, regarding
health and safety issues. These areas are list below in order of their respective importance:
Fire Safety.
Fire risk arises due to inappropriate supervision & maintenance of fire fighting
equipments along with separate gas cylinder storage area.
Violence at work, Vehicle hazard & Slip, trip and fall.

Due to high production pressure it was observed, supervisor were using verbal
abusive language to workers that is creating stress among workers which can lead to
violence at work .Also there were no such procedure of reporting was observed in
such cases. Other issues observed were collision of forklift truck (FLT) with workers
and equipment due to congested space and slip trip and fall risk that is purely related to
office inappropriate maintenance.
Working Practises.
Lack of safety awareness in workers, operators and supervisor was observed during
inspection of board section which can easily rectified by giving them proper training
regarding proper usage of PPE, Manual handling and etc.
Machinery Safety.
The risk injury to operators & co-workers from manually operated machinery was
observed that can be easily be improved by simple engineering design changes.
Welfare facilities & Safe Environment.

Inadequate cleanliness in toilets & hand washing facilities was observed. Storage of
clothing and rest room provision should be improved by refurbishment
By improving above mentioned areas we can easily reduce the risk of accidents & ill health issues
which can help us in improving current morale of workforce, also make workplace happier and well
motivated for employees.
Following pros & cons have to be faced in future prospective by higher management whether they
implement these raised issues or not:
2.1-Advantages
1-By implementing these raised issues increases efficiency and productivity of organisation.
2-It will create positive safety culture in organization.
3-As preventive cost is much low as compared to accidental cost.
2.2-Disadvantages
A-Not implementing will lead to possible enforcement action on breaches of legislation issues.
B-further if accident happens, companys reputation which makes it hard to win contracts in
the future.
c-Increase direct & indirect cost of accident including compensation payment to the injured
person,Repairs & replacement of damaged equipment, Replacement & retraining injured
workers,Medical expenses e.g. first aid, hospitalization & surgical operations,Legal expenses
e.g. lawyers fees, fines & penalties and etc.


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3-Main findings of the Inspection:
3.1-Fire Safety (Reference observations 1,2,3,4, 5 & 6 of observation sheet)
Number of fire risk was present e.g. risk of fire spread in case of emergency as fire
fighting equipments were not properly maintained, production related files stored under desk of
supervisor office, next to electrical sockets & cables, heap of wasted lamination sheets near CNC
machines (Skipper, Rover etc) & Cutting machines (Beam Saw),inappropriate storage of flammable
substances in machine maintenance room, also gas welding cylinder was present in maintenance
machine room that can cause fire & explosion in working area.
There represent possible breaches of the general provisions contained within Article 16 of ILO
Convention C155 and more specific obligation on employers regarding fire risks in ILO
Recommendation R 164,article 10.
In short term , Management should take immediate actions for overall maintenance of fire fighting
equipment i.e. inspection all fire extinguisher, fire alarm and detection systems e.g. smoke detector,
flame detector and water sprinklers. Make sure that files are at safe distance from electrical appliances,
waste removal on hourly basis by using waste trolley. All flammable items should be stored in fire proof
cabinets and provide missing sign boards as soon as possible.
In medium and long term, Management should do periodic monitoring after initial maintenance of fire
fighting equipment and training to all staff regarding fire hazards and about the ERP (emergency
response procedure). Conduct fire drill exercises periodically in peace time. Monitor files management
system, fire risk assessment, waste management conducted by area supervisor. Conduct tool box talk
on fire safety for workers & supervisors.
3.2-Violence at work, Vehicle hazard and Slip, trip & fall (Reference 12,16,17,18, and 19
observations of observation sheet)
Due to high production pressure it was observed, many unnoticeable or neglected hazards were
observed that can cause severe harm to working area such supervisor were using verbal abusive
language to workers that is creating stress among workers which can lead to violence at work and no
such procedure of reporting was observed in such cases. Other issues observed were collision of
forklift truck (FLT) with workers and equipment due to congested space and slip trip and fall risk that is
purely related to office inappropriate maintenance of working area.
There represent possible breaches of Article 16 of ILO Convention C155 and ILO Recommendation
R 164, article (10a) which states that employer should provide safe working environment along with
breaches regarding vehicle collision and slip trip and fall of WHSWR Workplace (health, safety and
welfare) regulation-1992 and ILO C167 (Construction safety).
In short term, Management should brief staff to problems that are likely to occur regarding violence at
work, Consultation to both victim & offender, audible alarm system and beacon light & banksman while
FLT is manoeuvring in working premises and high visibility jackets for workers to avoid vehicle collision
and alert staff about slip, trip & fall hazard & proper housekeeping and maintenance of production
offices.


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3.2-Violence at work, Vehicle hazard and Slip, trip & fall (Reference 12,16,17,18, and 19
observations of observation sheet) Continue
In medium and long term, Management make sure by proper monitoring make sure no problem
reoccurrence. Introducing De-escalation techniques i.e. zero tolerance for work place violence and
setting up procedure for proper reporting of such events, strict policy of not using abusive substance,
alcohol and installing CCTV cameras and proper training of FLT driver & banksman, segregation of
paths for vehicles & workers by changing layout plan.
3.3-Working Practises (Reference observations of 7,8,10 of observation sheet)
Lack of safety awareness in workers, operators and supervisor was observed during inspection of
board section as operators & co-workers were observed not lifting heavy bundle of lamination sheets
correctly, improper loading & unloading of work pieces at stationary conveyors, as worker try to jump
main manually moving conveyer in designated moving area. All these unsafe practises lead different
musculoskeletal injuries of fracture, dislocation, sprain of muscles, tendon or ligament. Mechanical
injuries including of lower back injuries, cuts and abrasion and etc.
There is possible breaches of ILO Convention C155 and ILO Recommendation R 164 as to provide
training to workers and ensure that employees cooperate with the employer.
In short term , Management should take immediate actions by installing beacon to moving conveyor
and provision of safety cones during transfer of work pieces to other station and installation of warning
sign boards, Correct posture techniques should be followed and ensure that sign boards of lifting
techniques are installed at work.
In medium and long term, Management provide training regarding safety of musculoskeletal hazards,
Safe Manual handling and use of proper PPE should be arranged for workers & operators.
3.4-Machinery & Equipment (Reference observations of 9, 11, 14 and 19 of observation sheet)
Several items of automatic and manually operated machines and equipment are in dangerous state for
workers such as vibration and noise of cutting machines, Lipping and CNCs along with presses, veneer
stitching and calibration machine, un adjustable DSE, slippery, damaged, painted metallic stairs that can
lead to upper limb disorder (WRULDs), acute & chronic physical & psychological effects on workers and
mechanical injuries or cause of dangerous accidents.
There represent possible breaches of ILO Recommendation R 164, article (10a) which states that
employer should provide safe equipment without the risk to employees health i.e. practically reasonable.
In short term, Management should provision of relative PPE i.e. Ear protection devices and safety
gloves, coverall, safety gloves, regular maintenance checks regarding machinery especially manual
machinery and equipment.
In medium and long term, Management provide guards to be installed on manual machines, training to
workers regarding how to operate machinery safely, behavioural survey should be conducted to ensure
proper usage of PPE, Administrative control i.e. lowering frequency & exposure time of noise and
vibration hazard by giving proper rest time & changing shift after regular interval of time, Engineering
Control i.e. Design changes in machines, making them less vibrant & sound proof.


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3.5-Welfare Facilities & Safe Environment (Reference 15,20,21, and 22 observations of

observation sheet)
Many basic welfare facilities were missing during inspection such as insufficient cleanliness of hand
washing & toilet area that causes risk of biological exposure, no facilities for changing clothes, rest room
that can cause possible risk of cross contamination of personal clothing, inadequate provision of medical
equipment and first aid room in case of emergency or accidents. Inadequate/poor ventilation that leads
to fatigue and discomfort caused by thermal stress at cutting machinery area & working area of presses
in adverse weather conditions i.e. in Summers.
There represent possible breaches of ILO Convention C155 and ILO Recommendation R 164, under
employers responsibilities.
In short term, Management should ensure provision of First aid box, Medical emergency phone numbers
to be posted at every notice board, immediate cleaning of toilet rooms and hand washing area, provision
of desk fans to operators.
In medium and long term, Management Provision of trained medical staff, first aid room and adequate
medical equipments, personal locker to workers, convert unused office in rest room and changing
clothes room, installation of central Air conditioning (HVAC) system and Regular toilet cleaning schedule
to be maintained and posted on notice board of toilet area.
4-Conclusions;
My inspection leads to conclusion that Board section is fairly well run by management with some
excellent and appreciable examples of LEVs (Local exhaust ventilation) system and Manual &
automatic Pallet trucks operation & maintenance, good provision of natural & artificial lighting system,
Strict No Smoking policy, machinery equipped with guards and also with trip devices, testing of electric
equipment and latest electric protection systems.
The most significant hazards and their causes & consequences are mainly related to Fire, violence at
work, vehicle hazard, Slip, trip and fall, unsafe working practises, machinery Safety and poor welfare
facilities & working environment. Actions and recommendation on these findings to be taken are
Simple in house trainings which provide high impact at low cost along with better level of supervision
to limit bad practices that again is relative low cost measure if we consider the benefits management
going to reap. Attention to safety will not only improves safety culture but also raises the horizon of
new ways of thinking about safety to new level in order to achieve ILO-OSH 2001, HSE management
standard as it is morally, socially and economically beneficial to organization in longer terms.


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5-Recommendations:
Recommendation Likely resource implications Priority Target date
5.1-Fire Safety
Periodic monitoring, maintenance The estimated immediate cost is High 1 month

of fire fighting equipment and Rs-200,000/-
training to all staff regarding fire
hazards and ERP (emergency
response procedure). Conduction
of fire drill.
5.2-Violence at work, Vehicle hazard & Slip, trip and fall.
Provision of audible alarm system The estimated immediate cost of High 1 month
and beacon light to FLT , high PPE, training and CCTV
visibility jackets , CCTV installation, installation is Rs-2000/-per
High level of supervision ,Training worker.
and Consultation to workers ,Strict (In-house training reduces the
not using abusive substance & cost of trainer and employee time)
alcohol policy.
5.3- Working Practises
Training regarding safety of The estimated immediate cost of High 1 Month

musculoskeletal hazards, Safe training( Rs-30,000) per month
Manual handling and use of proper salary of safety supervisor,
PPE, Correct loading & unloading Simple 1 hour training daily by
posture techniques should be competent safety supervisor, In-
arranged for workers & operators. house training reduces the cost of
trainer and employee time.
5.4- Machinery & Equipment
Provision of relative PPE , The estimated immediate cost is High 1 Week

Engineering Control i.e. guards to Rs-100,000/-
be installed on manual machines
and less vibrant & sound proof
machines, Administrative control
i.e. proper rest time & changing shift
after regular interval of time


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Recommendation Likely resource implications Priority Target date
5.5-Welfare facilities & Safe Environment
Provision of First aid box, Medical The estimated immediate cost is Medium 1 Week
emergency phone numbers to be Rs-5000/- for cleaning and first to
posted at every notice board, aid box 6 Months
cleaning of toilet rooms and hand The estimated immediate cost is
washing area, desk fans, personal 20XRs-2000/- per machine Fan
locker ,Rest room and changing Zero cost on Lockers using
clothes room, installation of central damaged/extra pieces available
Air conditioning (HVAC). in warehouse.
The estimated long term HVAC
system is 1-Million

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INTERNATIONAL GENERAL

CERTIFICATE Candidate report template

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

1.1-Floor Lay out Plan of Board Section

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

1.2-Process Layout Plan in Board section

Process flows in Board Section

Process Flow 1 (veneer pressed C.B)

PVC Lipping Manual lipping Wood lipping

Process flow 2 (Formica + veneer sheets pressing)

Press Beam Saw PVC Lipping CNC

Process flow 3 (Laminated chip board)

Beam Saw PVC Lipping CNC

Process flow 4 (Veneer pressed C.B) with CNC Working

PVC Lipping Manual lipping Wood lipping

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

Violence at work, Vehicle hazard & Slip, trip and fall.

Welfare facilities & Safe Environment.

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

3.1-Fire Safety (Reference observations 1,2,3,4, 5 & 6 of observation sheet)

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

3.3-Working Practises (Reference observations of 7,8,10 of observation sheet)

3.4-Machinery & Equipment (Reference observations of 9, 11, 14 and 19 of observation sheet)

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

3.5-Welfare Facilities & Safe Environment (Reference 15,20,21, and 22 observations of

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

Recommendation Likely resource implications Priority Target date

Periodic monitoring, maintenance The estimated immediate cost is High 1 month

5.2-Violence at work, Vehicle hazard & Slip, trip and fall.

5.3- Working Practises

Training regarding safety of The estimated immediate cost of High 1 Month

5.4- Machinery & Equipment

Provision of relative PPE , The estimated immediate cost is High 1 Week

UNIT IGC3 THE HEALTH AND

Date of Review: 16/Septemeber/2012.

Recommendation Likely resource implications Priority Target date

5.5-Welfare facilities & Safe Environment

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