1.

0 ABSTRACT

A risk assessment was conducted in Nestl Manufacturing Malaysia Chembong Ice Cream

factory. The purposes of this assessment are to identify hazards that may potential cause harm to

fitters and others in the place of assessment; to assist the management to evaluate the chances of

that harm to the fitters and the possible severity that could come from the hazards; and to provide

a guide to management to make decision on planning, implementing and monitoring preventive

measures to ensure that the risks are adequately controlled at all times. The hazards identification

and risk assessment was carried out in Ammonia Refrigeration Plant. The methods used for

hazards identification include workplace inspection, referring to non-major hazard CIMAH report

and from interview and survey from fitters involved in this process. There are totally 10 hazards

identified during the hazard identification which include ammonia gas release, physical space

constrain, fall from height, crush by falling hazard, slip and fall, explosion, electrical shocked,

expose to chemical, expose to noise, and ergonomic hazard. The most critical safety hazard is

ammonia gas release with risk rating of 8. Meanwhile, the most critical health hazard is chemical

exposure hazard which is the Ammonia work station with risk rating of 8. The control measures

that recommended for the ammonia gas release hazards are implementation of safety features at

equipment, gas sensor detectors, periodic maintenance, warning signage, review of work

instructions, permit to work system, LOTO, provide appropriate PPE and training. Control

measures for most critical health hazard are training on the correct way to handle ammonia

maintenance and oil drainage, review of work instruction, baseline for health surveillance,

lockout / tagout system, stand-by person, training and provide appropriate PPE.
2.0 INTRODUCTION

2.1. Company Overview

Formally known as Nestl Cold Storage Sdn Bhd, the company name was changed to

Nestl Manufacturing (Malaysia) Sdn Bhd in year 2003. Nestl Chembong Ice Cream factory

manufactures ice cream, ice confection and frozen confection products. The factory (NMM-CE

Ice Cream factory) was built in year 1996 and first commercial production started in March 1997.

This factory is certified for OHSAS18001:2007 and MS1722: Part 1 for Occupational Safety and

Health Management System and ISO14001:2004 for Environmental Management System. This

factory is located at Jalan Perusahaan 4, Kawasan Perindustrian Chembong over a total land area

of approximately 35,500 sq meters with a build up area of 5,146 sq meters. The head office in

Nestl Malaysia is located in Menara Surian, Petaling Jaya, Selangor.

The operation of business is managed by Factory Manager. He is assisted by his Factory

Leadership Team from various departments namely, Factory Controller, Production Manager,

First Line Managers, Industrial Performance Manager, Senior Application Group Executive,

Plant Engineer and executives, Senior Quality Assurance Executive, Resource Unit Executive,

Warehouse Executive, Supply Chain Executive, SHE Executive and Senior Human Resource

Executive who indirectly report to Factory manager. This presented in Figure 1. The work force

in this factory consists of approximately 26 management staffs which included the executives,

senior executives and managers and 158 non-management staffs such as operators, technicians as

well as contract partners. According to Occupational Safety and Health (Safety and Health

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Officer) Order 1997 (3) (j) (1), the employer shall employ a safety and health officer if any other

manufacturing activity other than the manufacturing activity specified in subparagraphs (f) to (i),

employing more than five hundred employees. Due to total number of employees in this factory

less than 500, therefore a SHE Executive is hired to ensure the compliance to legal and internal

safety, health and environment requirements. The SHE executive is directly report to Factory

manager and indirectly report to Group Safety & Health Manager who is based in Head Office.

Besides, the safety and health committee is established to ensure the safety and health program in

this factory effective. The Safety and Health Committee organization chart as presented in Figure

2.

Figure 1: Factory Leadership Team

Figure 2: Safety and Health Committee

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2.2. Process Overview

In NMM-CE Ice-cream factory, there are few operations which include warehouse

operation, ice-cream production, ammonia refrigerant plant, cold room for ice-cream storage, and

distribution. There are different safety and health hazards in each of these areas. For this

workplace assignment, the ammonia plant has been selected.

Ammonia Plant is the heart of the operation in Ice-cream factory to support ice-cream

processes and supply low temperature for finished goods storage in - 25C. Ammonia (NH3) is

commonly used to lower temperatures below freezing point and in the manufacture of synthetic

ice. The ammonia refrigeration process is operating by changing the state of the cooling medium

in order to remove heat from a cold environment or body and release it into a warmer

environment. The refrigerant is caused to circulate in a closed system, circulation being

maintained by either compression or absorption. Compression systems are in widest use such as

in these a gaseous refrigerant is compressed by a compressor allowed to condense in a heat

exchange unit (condenser), heat being given off in the process, and led as a liquid through an

expansion valve or a throttle system into an evaporation chamber (evaporator), in which the

refrigerant absorbs heat while returning to the gaseous state, after which it is drawn again into the

compressor, and the cycle is repeated.

Refrigerant Process flow diagram is presented in Figure 3 below.

Figure 3: Ammonia Plant Refrigerant System Flow Chart

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3.0 OBJECTIVE

The purposes of this report are as follows:

To identify the critical hazards that may potential cause harm to operators in the place of

assessment;

To evaluate the possible severity that could come from the hazards; and

To highlight hazards and control measures to the management to ensure that the risks are

adequately controlled at all times.

4.0 METHOD

The definition of hazard is a source or a situation with the potential for harm in terms of

human injury or ill health, damage to property, damage to the environment or a combination of

these (2). Hazards have the potential to cause people injury or ill health. Therefore, it is important

to identify hazards at the place of work before the risks associated with these hazards can be

assessed and if there are no controls exist or existing control are insufficient, effective controls

should be implemented based on the control hierarchy. In order to reduce the risks of incidents,

an organization need to apply the process of hazard identification and risk assessment to

determine the control measures.

4.1. Method Used for Hazard Identification

Prior to hazard identification, ammonia plant area layout was obtained to identify the area

that going to do the assessment. Hazard identification should aim to determine proactively all

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sources, situation or behaviors or combination of these arising from this workplace with potential

for harm in terms of operator injury or ill health.

The following methods are used to identify safety and health hazards at NMM CE Ice-

cream factory:

I. Workplace inspection / observation

A workplace inspection checklist has been developed and a record of workplace

inspection checklist is presented in Appendix A. This checklist includes most of

the potential hazards that could be found at the place of work which including

physical, electrical, chemical, biological, mechanical as well as psychosocial or

ergonomics.

II. Review of Non CIMAH report

Ammonia is a hazardous substance that exists in this factory, which falls under

scheduled 1 of part 2 in Occupational Safety and Health (Control of Industrial

Major Accident Hazards) Regulations 1996. Although the quantity does not

exceed threshold quantity that specified by the regulation, the substance is a

finished product from supplier that is received at -28C and at pressure 14 Bar. In

the event of emergency situation, a large quantity of NH3 gas or liquid will be

discharged and give rise to a dense widespread fog. Hence, the Non CIMAH

report has been referred and studied to obtain information on the composition of

the hazardous substances, refrigerant process, safety management system, and

emergency response plan. The Non CIMAH report is presented in Appendix B.

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 III. Interviewed with staffs

The fitter or technician were interviewed and simple survey has been carried out

about the safety and health hazards from the task, working procedures and usage

of personal protective equipment. The example of the questions is shown in

Appendix C.

4.2. Method of Risk Assessment:

Risk is the determination of likelihood and severity of the credible accident/event

sequences in order to determine magnitude and to priorities identified hazards. In other words,

risk is the combination of the likelihood of an occurrence of a hazardous event or exposures and

the severity of injury or ill health that can be caused by the event or exposures. In this report,

semi-quantitative risk assessment method has been used and the risk matrix as per presented in

Table 3 below is used to assess the risk posed by the safety and health hazards in this workplace.

4.2.1. Likelihood of an occurrence

This rating is based on the likelihood of an event occurring. Each category is represented by

a rating value ranged from 1 to 4. The value of likelihood is determined based on the past

accident records of similar case that happened in this factory as well as similar cases that

happened in other factories in Malaysia. The opinion from the fitter also will take into

consideration to determine the rating of likelihood. Table 1 indicates likelihood using the

following values:

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 LIKELIHOOD CRITERIA RATING

Most likely The most likely result of the hazard being realized 4

frequently

Likely Has a good chance of the hazard being realized 3

occasionally

Unlikely Has not been known to occur, but only rarely 2

Highly unlikely Is practically unlikely and has never occurred 1

Table 1: Likelihood of an occurrence

4.2.2. Severity of hazard

The severity can be divided into 4 categories. Severity is based upon increasing level of

severity to an individuals injury, health effect, or to property. Each category is represented by a

rating value ranged from 1 to 4. It is based upon the increasing level of severity to an individuals

injuries. This rating is based on the severity of the past incidents and opinion of the experienced

people. Table 2 indicates severity by using the following table:

SEVERITY CRITERIA RATING

Permanent disability Serious injury that resulting to permanent disability / 4

/ Fatality long term ill health effect (cancer, irreversible hearing

loss) / resulting fatality

Major injury Major injury that resulting to lost time / short term ill 3

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 health effect (high fever, alkaline burn, sore eyes, MSD)

Minor injury Injury that requiring medical treatment / resulting 2

temporary ill health discomfort (headache, dizziness,

nausea)

Negligible injury Injury will only resulting near miss / first aid / no ill 1

health effect

Table 2: Severity of hazard

4.2.3. Assess the risk

In summary risk can be assessed by using the following equation:

Risk = Likelihood x Severity

To use the risk matrix as presented in Table 3, first is to determine the severity of hazard

that best describes the outcome of the risk by referring to column. Then follow the likelihood row

to find the description that best suits the likelihood that the severity occurred. Then risk level is

given in the box where the row and column meet.

SEVERITY (S)

Permanent
Negligible Minor Major
LIKELIHOOD (L) Disability /
injury (1) Injury (2) Injury (3)
Fatality (4)

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 Highly Unlikely (1) 1 2 3 4

Unlikely (2) 2 4 6 8

Likely (3) 3 6 9 12

Very likely (4) 4 8 12 16

Table 3: Risk Matrix

The risk ranking can be used to prioritize necessary actions to effectively manage workplace

hazards. Table 4 below determines priority based on the following ranges:

RISK DESCRIPTION ACTION

8-16 HIGH A HIGH risk requires immediate action to control the

hazard as detailed in the hierarchy of control. Actions taken

must be registered in the corrective and preventive action

plan including date for completion.

3-6 MEDIUM A MEDIUM risk required a planned approach to controlling

the hazard and applies temporary or short term solution if

required. Actions taken must be registered in the corrective

and preventive action plan including date for completion.

1-2 LOW A LOW risk is considered as acceptable and further

reduction may not be necessary. However, if the risk can be

resolved quickly and efficiently, control measures should be

implemented and recorded.

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 Table 4: Priority Table

5.0 RESULT AND DISCUSSION

5.1. Safety and Health Hazards been Identified in Ice-Cream Production

By using the three methods of hazard identification stated in section 4.1, following are the

list of hazards that can be identified in Ammonia Plant.

5.1.1. Safety Hazards

5.1.1.1. Accidental Ammonia gas released

Ammonia gas is lighter than air; however release of ammonia at the pipelines or

valves will rapidly absorb moisture from air and form a visible dense white cloud.

Explosion could be rarely happened.

5.1.1.2. Physical Hazard

The physical hazard is posed by the space constrain at elevated platform where the

fitters head may easily hit on the pipeline.

5.1.1.3. Fall from Height Hazard

This is due to the exposure in the building where maintenance and repairing work

required at first and second floor.

5.1.1.4. Crush by falling Hazard

This is due to fitters unloading of ammonia gas cylinder from the lorry by using

forklift to charging area. Unsecured gas cylinder can slip away from the forklift

causing crush injuries to the fitter around.

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 5.1.1.5. Slip and Fall Hazard

This is due to accumulation of condensate water and oil residual on the floor area

where the fitter expose to slippery floor.

5.1.1.6. Explosion Hazard

Equipment failure and pressure vessels rupture will lead to an explosion and could

wipe off the whole building. The contributing causes could be due to external

corrosion, pressure relief valve failure, manufacturing defect, external fire, or human

error.

5.1.1.7. Electrical Shocked Hazard

Using powered hand tools, welding equipment, or repairing compressor motor

which potentially contact with energized source can cause electrical shock to the

fitters.

5.1.2. Health Hazards

5.1.2.1. Exposure to Chemical Hazard

Ammonia is toxic. Exposure to ammonia above 50 ppm can result irritating to the

nose, mouth, throat and causing coughing. At a higher concentration of 300 to 500

ppm, it become a medical risk and can immediately dangerous to life and death.

5.1.2.2. Exposure to Excessive Noise

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 Noise is generated in Ammonia Plant by the compressor motor. The noise level is

more than 95 dBA. Impairment hearing loss and psychological stress are the health

effects of noise hazard.

5.1.2.3 Ergonomic Hazard Low Back Pain

Lifting heavy loads can caused fitters to have low back pain which lead to muscle

injuries. Exposure

From the risk assessment, the prioritization of the hazards is presented in Table 3 below as well

as the risk rating.

NO HAZARD LIKELIHOOD SEVERITY RISK

RATING
1 Accidental ammonia gas released 2 4 8

2 Physical Hazard (space constrain) 2 2 4

3 Fall from height hazard (working 1 3 3
on elevated platform)
4 Crush by falling hazard (unloading 1 3 3
of NH3 gas cylinder)
5 Slip and fall hazard (expose to 2 1 2
slippery floor)
6 Explosion hazard (equipment or 1 4 4
pressure vessel rupture)
7 Electrical shocked hazard (using 1 4 4
power hand tools or welding
equipment)
8 Chemical hazard (expose to 2 4 8
irritating chemical during regular
maintenance or ammonia leakage)
9 Exposed to excessive noise hazard 1 4 4
(expose to noise level above 90
dBA)
10 Ergonomic hazard (lifting heavy 2 3 6
load)
*Picture of this hazard is presented in Appendix D

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 Table 5: Risk Rating of Safety and Health Hazards

5.2. Hazard Prioritization Based on Risk Rating

Based on the results of risk assessment, accidental ammonia gas release, exposed to

chemical hazard and exposed to noise hazard in the Ammonia Refrigeration Plant are the highest

risk rating for safety and health hazard among the other identified hazards. The risk rating is 8

respectively. The other hazards also need to be addressed as soon as possible such as ergonomic

hazard while lifting heavy load and fall from height hazard while working on elevated platform.

The recommended corrective and preventive actions will be discussed on section 6.1.2.

Safety Hazard

Accidental ammonia gas release is the critical safety hazard found in this workplace.

According to the ammonia fitter, ammonia leaks can be a problem in any refrigeration system.

Mechanical seals and pressure relieve valve can be failed and allow ammonia escape into the

atmosphere. Ammonia is a colorless gas, lighter than air and with pungent smell, when mixed

with air in the ratio of 16% to 25% of gas by volume will form an explosive mixture. Explosive

combustion can occur in flammable mixtures in the work space, it is possible to cause structural

damage in the work space due to the pressure wave. The details on the characteristics of

Ammonia in the form of material safety data sheet (MSDS) are presented in the Appendix

There were few incidents that relate to gas leak in ammonia refrigeration plant occurred

across factories in Malaysia. The common root causes are human error and failure of safe relief

valve functioning. In worst scenario, a catastrophic rupture event that release 800 ppm

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concentration of ammonia gas will form a vapor cloud at maximum 23.94 m in diameter and

possible disperse to a distance of 112.9 m in 10 second at wind speed 6.7 m/s.

Health Hazard

Exposed to chemical hazard is the most critical health hazards found in this workplace.

This hazard is the highest risk rating which is 8 and is categorized as high risk. According to the

chemical health risk assessment (CHRA) report, ammonia gas is the most hazardous chemical

used in this factory. Ammonia is an inhalation irritant and caustic effect. This can create a

problem for most of us because human cannot tolerate exposure to large amounts of this

refrigerant very well. The hazards of ammonia are mainly connection with the irritating

properties, corrosive properties at high concentration. Over-exposure can become a medical risk

and can immediately dangerous to life and death at a higher concentration of 300 to 500 ppm.

Ammonia can enter into human body through inhalation / ingestion, skin contact, or splashes into

eyes.

a) Inhalation / ingestion

Ammonia has an irritating effect at higher concentration. Rapid vaporizing liquid

can displace life supporting oxygen and cause irritation. The symptoms are

difficulty in breathing and eventually collapse and become fatal.

b) Skin Contact

Exposure to liquid ammonia can cause alkaline burns because of corrosive

c) Splashes into eyes

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 Splashes of ammonia liquid into eyes or higher concentration of gas are particular

dangerous. The rapid penetration of ammonia into the ocular may result in

perforation of the cornea and even death of the eye-ball.

5.3. Impact of the Most Critical Safety and Health Risks to the Organization

The identified hazards will not only affecting to the workers but it will also bring impact

to the organization. According to Occupational Safety and Health Act (OSHA1994), it is the duty

of employer to ensure that the workplace is safe and free from health risks in order to prevent

accidents and illness in the workplace. The impact of the most critical safety and health risks to

the organization can be in term of monetary such as direct cost and indirect cost involved by

referring to Accident Cost Iceberg Model as presented in Appendix E and also the non-monetary

such as the reputation of the organization and also the trust from the customers or consumers.

Both most critical safety and health risks will cause injury to those exposed to these

particular hazards. The most severe consequence for most critical safety hazard could be the plant

was blown out and results permanent disability or fatality. The most critical health hazard could

be victim suffered asphyxiation that could result fatality. The organization has to spend for direct

costs such as compensation or medical fees which are exceeded the insurance coverage of the

victim.

Besides, there are also indirect costs involved. If accident happened, this will cause the

operation stop for investigation by Safety and Health Committee and/or Occupational Safety and

Health Officer if requested by the authority. This will result in delay of product supply to

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customer and not meeting customers requirements. This will end up of losing the customer. In

case where the ammonia refrigeration system was collapse and unable to continue the normal

operation, the organization needs to put a greater investment, expertise, parts supplies and

replacements in order to resume the normal operation. This will take lots of time and cause the

production slowdown and not able to meet customer requirements.

Other than that, if the victim suffers health injuries from the irritant chemical, the

organization needs to arrange a series of medical treatment, rehabilitation and back to work

program in order for victim to go back to work as normal fitter or to a lighter work task. Based on

the Accident Cost Iceberg Model, the visible part of Iceberg is representing the insured cost

meanwhile the hidden part is the uninsured cost which is 8 to 36 times greater than the insured

cost.

The organization will report the annual performance report to the shareholder and safety

and health performance is always one of the key focuses of the shareholders. If accident

happened frequently in the organization, customer and consumers will have the perception that

the organization is not taking care of their employees especially the organization is certified with

Standard OHSAS18001 and ISO14001 and will not invest further or buy the products of the

company.

6.0 RECOMMENDATION

6.1. Proposed Control Measures for Each Critical Safe and Health Hazards

Hazard should be controlled at their source. According to Hierarchy of Control, first we

should try to eliminate the hazard. It is the best way of protecting workers. Second is by

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substitution where doing the same work in a less hazardous way. Third is engineering control

such as isolation, automation, barriers, absorption, dilution etc. Next is an administrative control

such as safe work system, training, job rotation, etc and lastly is Personal Protective Equipments

where other controls measures are not feasible and where additional protection is needed.

6.1.1. Control Measures for Critical Safety Hazard

From the assessment, the most critical safety hazard is ammonia gas release hazard which

is high risk. In order to control this hazard, elimination and substitution is not feasible. The

following control measures are recommended and being implementing to reduce the risk:

a) Engineering Control

The pressure vessels were designed, fabricated, erected, inspected and

tested in accordance with recognized standards. Besides, all pressure

vessels has certificate of fitness and approvals from the Department of

Occupational Safety and Health (DOSH)

The sphere was designed to sustain pressure imposed when it is filled to

the maximum permitted level and a pressure superimposed equal to the

vapor pressure at the maximum design pressure and temperature

Safety features i.e. pressure relief valve, temperature and pressure gauges

are incorporated in the vessels, pipelines, cylinders, hose connections and

fittings.

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 Gas sensor detectors to audible and visual Alarms were installed to

monitor of toxic and flammable concentration levels in all hazardous areas,

e.g. plant room, production, cold room, etc.

Equipped with emergency exhaust ventilation stack to dispose gas release

from pressure relief valves

Non-destructive test i.e. hydrolic test was conducted and tested at 500 to

900 psi

Maintenance and inspection for the Ammonia Refrigeration System

including corrosion controls, monitor existing equipment, lines fittings, oil

drainage system, manual / automatic shut off valve and pressure relief

valve

b) Administrative Control

Work instructions for ammonia maintenance work were established to

formulate standard practices to minimize human error and breakdown

Permit to work system was introduced to control certain types of works

which are identified as potentially hazardous, e.g. maintenance of

ammonia compressors

Visible warning signage are display to warn employees, contractors or

visitors of the possible hazards and to prevent unauthorized personnel

from entering the work area

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 Emergency response plan (ERP) and full site evacuation procedure are

established, it should be reviewed to cover any changes in the operation /

process

Emergency drill e.g. fire evacuation and ammonia drill should be practiced

more often with cooperation from the HAZMAT team in Fire & Rescue

Department

Competency based training shall be implemented for the ammonia fitters

and engineering personnel to ensure they have the proper knowledge and

skills to operate the refrigeration system

Ammonia safety audit was carried out in yearly basis and all audit gaps

should be follow up and closed on time

c) Personal Protective Equipment (PPE)

Appropriate PPE are provided in the work area i.e. full face piece with

chemical cartridge respirator, self-contained breathing apparatus (SCBA),

chemical protective suit, safety shoes, ear muffs / ear plugs, rubber gloves,

safety goggles, etc.

Emergency eyewash and shower system are installed at each floor in the

plant

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 Besides of the above control measures, Log out Tag out (LOTO) system shall be

implemented where the energy sources (e.g. electricity, ammonia gas, etc.) is isolated and locked

by the fitter who will carry some maintenance work. The isolation point for LOTO should be

clearly mark on the machine / equipment to let the fitter know where should he isolated and lock

so that nobody except the fitter holding the key is allowed to open the lock and turn on the

machine once the maintenance is completed.

6.1.2. Control Measures for Critical Health Hazard

From the assessment, the most critical health hazard is exposed to irritant chemical

hazard which is high risk. In order to control this hazard, elimination and substitution is not

feasible. The following control measures are recommended and being implementing to reduce the

risk:

a) Engineering control

Isolate of the Ammonia Refrigeration Plant with other working areas i.e.

Production, Warehouse, Cold Room, etc.

LOTO system shall be implemented to isolate energy sources during

maintenance work

Periodic maintenance of all safety features equipment including full

calibration test and function test must be carry out to prevent any faulty

reading or defect

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 The gas sensor detection level should be typically set at range 25-100 ppm

to alert the people around of the ammonia leak

b) Administrative control

Health surveillance for all ammonia fitters should be carried out

periodically to monitor blood toxic level, lung function, hearing frequency,

etc.

The fitters medical and occupational history should be always updated

and record keeping

Only experienced and trained fitter to be authorized carry out maintenance

work and oil drainage

Permit to work system should be implemented to address any potential

hazardous event before the work started

Watcher or stand-by person should be in place to supervise the work

especially during breakdown / plant shut down maintenance

c) Personal Protective Equipment (PPE)

Appropriate PPE are provided in the work area i.e. full face piece with

chemical cartridge respirator, self-contained breathing apparatus (SCBA),

chemical protective suit, safety shoes, ear muffs / ear plugs, rubber gloves,

safety goggles, etc.

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 Emergency eyewash and shower system are installed at each floor in the

plant

In term of preventive action, basically Baseline Health surveillance is recommended to be

established. It is similar with the noise surveillance program. The purpose Baseline health

surveillance is to establish a base against which changes in health care status can be evaluated,

not to prevent people from performing work. Periodic health surveillance should be conducted on

all fitters in the area exposure to ammonia gas. The content of the assessment should be similar to

that outlined for the baseline. Periodic follow-up should be done to determine the condition of the

fitters and if found any problems, appropriate action such as review the work procedures or

workstation.

6.2. Review on Effectiveness of Control Measures

All the control measures are requiring to be reviewed in order to determine the effectiveness

in managing the risk. The output of the reviewing process will be considered as an improvement

program.

The work instructions for maintenance should be reviewed. The steps of machine shut down

and start up shall be clearly stated in the procedure to ensure the applied LOTO and machine

guarding are always in place.

Inspections can be done during the beginning of the shifts by the fitters or periodical

inspection by Safety and Health Committee for any defects and abnormalities and reports to the

Engineering Manager immediately. Besides, during ammonia safety audit or OHSAS18001

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internal audit, it is necessary to check the effectiveness and condition of all the safety features

e.g. pressure relief valve, gas sensor detectors, manual shut off valve, etc.

The competency of the fitters is important in order to carry out the job safely. Competency

can be developed or built through education and training. Before conducting the training, the first

step is to establish a Training Needs Analysis (TNA). The purpose of the TNA is to identifies the

difference between actual and the optimum condition. Then, review current work instruction and

conduct competency based training to the fitters. The effectiveness of the education and training

program can be done by imposing the pre- and post-test.

The effectiveness of warning signs installed as a part of the administrative control must be

made as per the standard, clear, bright, concise, visible, readable and located near the hazard.

Monitoring of health status of every staffs in work area can assist to identify any

possibility of any occupational disease or illnesses. If the results showing any signs of

occupational diseases or illnesses from activities in this area, this means the control measures are

likely to be not effective. Periodic walk-through inspection is also important to identify the

potential hazard and to maintain close contact with the operators. The walk-through inspections

record should be kept with the date of the inspection and discussed the finding with the

management during the weekly, monthly meeting and Safety and health committee meeting

which is every quarterly. Follow-up should be initiated to correct the problem identified.

Behavior observation and feedback, BOF, should be implemented to monitor and review

the effectiveness of the recommended control measures. A critical behaviors checklist will be

established based on the area and they are required to perform behavior observation and feedback

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to his colleagues on a scheduled time. During the observation and feedback, observer will catch

observee do things correctly and give positive reinforcement. If the observer found at-risk

behavior, observer will discuss with the observee to get the activator and come out with the

action to change the at-risk behavior.

6.3 Benefits of Recommendation

The main purpose of the control measures and review programs is to ensure the operators

and fitters are safe and health in the workplace. It is stated in the OSHA 1994 that the employer

should provide a safe and healthy working environment to the employees. Besides, the hazards

control measures and effectiveness review programs will benefits a lot the organization and the

operators in term of safety and health and will help to ensure the smooth continuity of the

ammonia refrigeration system.

The hazard control measures as explained earlier such as engineering control and

administrative controls will help to reduce the exposure of the fitters to the hazards. Hence the

risk of the accident will be reduced. Reduction in accident will benefit the organization not only

in term of monetary as well as non-monetary. Time being waste for the investigation, spend time

to hire the new fitter and train them, invest to get parts supplies for replacement, compensation

payment are all categorized as monetary lost. In term of non-monetary, reputation of the

company will be affected by the accident and it will take time to rebuild the reputation and trust

from the customers and consumers.

The review of current work instructions and procedures and competency based training will

help to increase the awareness of the fitters on the safe working steps. Periodical walk-through

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inspection will help to identify the unsafe conditions in the workplace and ensure them work in a

safe manner. With the implementation of behavior observation and feedback, the fitters will be

always aware and conscious on the safe behaviors. If the observer found any at-risk behaviors

from the observee, feedback will be given to the observee and activators to be identified and

come out the solutions for the at-risk behavior.

Lastly, the benefit of the control measures and review programs explain above will provide

a safer and healthier workplace, positive attitude towards work and greater job satisfaction to the

operators as the work area and process has made safe.

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