Tarlac State University

College of Engineering & Technology

INDUSTRIAL ENGINEERING DEPARTMENT
Tarlac City

IE 533 – OCCUPATIONAL HEALTH &

SAFETY
ACTIVITY WORKSHEETS

Prepared by: Reviewed by: Approved by:

ENGR. M.N. ENGR. AJ S. LOPEZ DR. M.S. GALVEZ

BANTING Chairperson, IE Department Dean, College of Engineering & Technology
Faculty, IE Department
EXERCISE NO.1 – Hazards & Your Workplace.
Instructions: Identify the occupational hazards associated with the following pictures and
answer the questions provided under each picture.

1. Picture with an X through it shows a worker working around open containers of liquid
chemicals. His hands are in the liquid, he is not wearing gloves. There is liquid spilled on
the floor nearby and he is wearing open sandals. The workplace is clearly very hot.

Questions:
a) What is wrong with this picture? Can the chemicals the worker is working with affect his
health? How can they get into his body?
Answer:
_kjefadbffdkfkdnfkd_______________________________________________________
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b) What is the most common route of entry?
Answer:

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 c) If he inhales the chemicals, what effects can result?
Answer:
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d) If the chemical reaches target organs and causes problems (for example anemia), what type
of effect is that called?
Answer:
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e) If the chemical reaches target organs and causes problems (for example anemia), what type of
effect is that called?
Answer:

______________________________________________________________________________
___________________

f) Are there any other types of effects that could result from exposure to hazardous substances?
Answer:
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___

2. Picture shows a worker

sneezing. There is some
fine dust in the
workplace.

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Question:
a) If you often see your co-worker sneezing at work, what might you suspect? What steps
might you take to follow up on your questions? What actions could you take?

Answer:
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3. Picture of a worker whose hands show signs of dermatitis - the skin is red, blistered and he
is scratching his hands.

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 Question:
a) You see your co-worker's hands look like this. You suspect that it is dermatitis
from the chemicals he works with. You ask him about it but he says he is fine.
What can you do?
Answer:
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______

4) Picture of a worker working around animals and chemicals. Worker is in

personal protective equipment.

Question:
a) This worker handles animals and pesticides in his job. What types of hazards does he
face?
Answer:
_____________________________________________________________________
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 _____________________________________________________________________
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5. Picture of a worker at work with severe stomach pains.

Question:
a) Your co-worker has severe stomach cramps and feels very nauseous. You noticed
him eating lunch at his work area today and you know he works around solvents.
What are the possible causes of the cramping you might think of?
Answer:
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 _____________________________________________________________________
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6. Picture of an acid burn on an arm.

Question:

a) What type of effect is an acid burn?

Answer:
_____________________________________________________________________
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7. (No picture)

Question:
a) What is the reason that some hazardous substances only cause chronic health
problems a long time after the exposure occurred?
Answer:

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 _____________________________________________________________________
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EXERCISE NO.2 – Identifying Hazards.

Note to the instructor

For this exercise, students work in small groups of two to three people.

Instructions

The pictures below show different workplaces where a variety of hazards can be
found. Students will look at the pictures and imagine what sort of problems might
exist in each workplace. Write responses for each workplace on meta cards and post
them in the blackboard. Some of the major hazards associated with each of these
jobs are given below.

After discussing the jobs shown in the pictures, discuss the hazards in the students'
own building/ learning facility.

Discuss the hazards that may be associated with these jobs

1. Welder (Welding)

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Hazards:
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2. Mechanic

Hazards:

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 _____________________________________________________________________
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3. Port Worker

Hazards:
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4. Textile
Worker

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Hazards:
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5. Tractor Driver

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Hazards:
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6. Agricultural Worker

Hazards:
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7. Electronics Assembly Worker

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Hazards:
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8. Office Worker

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Hazards:
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9. Construction Worker

Hazards:

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 _____________________________________________________________________
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10. Miner

Hazards:
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Now that the students have begun to consider the possible hazards in different workplaces, ask
them to consider and discuss the hazards present in the university facilities. Students should
answer the following questions about the university facilities.

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(1) Describe the activities you do in the selected university facilities.

(2) What hazards do you know exist in your selected university facilities?

(3) Are there other conditions at work that you suspect may be hazardous, but you are not sure
about?

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EXERCISE NO.3 – Controlling Hazards.
Instructions: Students should work in small groups of three to five. Ask them to read and
discuss the case-study with their group, then answer the questions together with
their group. Discuss the groups' answers with the whole class.

A. Case-study

(This accident is based on a real work-related death. Only the names and dates have been
changed.)

On August 16, 1986, Juan Espinosa was assigned to work as an operator on a steel-slitting
machine at ABC Steel. Juan was killed on his first day operating the machine, which was also his
first day working at ABC Steel.

The machine

The steel slitter is a machine that cuts rolls of steel into strips. The steel rolls off a roller, is cut
into strands, and wound up again by a recoiler. The strands of steel on the outside of the roller
must stay taut (tight). Workers in the factory did not use the tension stand that was available to
keep the steel taut — instead they inserted pieces of cardboard by hand into the pinch-point of
the recoiler. (The pinch-point is the place where the flat steel coming out of the slitter meets the
rolling recoiler that rewinds the steel.) This kept the steel taut but was a very dangerous practice.
Workers were able to do this because there were no guards on the machine. The company knew
the use of cardboard was unsafe, yet they allowed workers to do it because it was quicker and
more economical.

Training

Usually a worker assigned to his job was given 30 days of training. Juan Espinosa did not
receive any training at all before his first day operating the steel slitter. Safety meetings were
held approximately every three months, but the content of the meetings was generally not
communicated to the workers.

Events leading up to the accident

On the day of the accident, slitter helper John Doe was told to work with Juan Espinosa
throughout the evening shift. Espinosa only spoke Spanish. Doe only spoke English. After five
hours of work, Doe went to another section of the plant to get another coil of steel. As he did
this, he heard an unusual noise from the machine. He ran back to the recoiler and saw Espinosa
wrapped in it, dead, with approximately 12 sheets of steel on top of him. Doe ran to the
emergency stop button which was approximately three metres away from the machine.

Espinosa was caught in the recoiler while inserting cardboard to keep the steel taut. He was
killed instantly.
Questions:
1) What do you think were the factors that caused this accident?
Answer:

Factors that caused the accident

a. Lack of machine guard

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 ________________________________________________________________________
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b. Lack of training for a new worker

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c. Language barrier

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d. Use of cardboard

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e. Lack of company safety policies

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f. Lack of management commitment to safety

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 2) How could this accident have been prevented?
Answer:

Here are some other suggestions for preventing accidents from unguarded
machines:

(a) Supervisors and employers have the responsibility to make sure they are complying
with local, national, or international machine-guarding regulations.

(b) Supervisors should be trained in machine guarding.

(c) Supervisors should be disciplined if their employees remove machine guards.

3) Are you familiar with the machine-guarding regulations in the Philippines (RULE
______ of Occupational Safety and Health Standards)?
Answer:
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4) What actions can you take to make sure machines/equipment you are using in your
laboratory rooms are properly guarded?
Answer:
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B. Control Methods

Instructions: Identifying problems and suggest solutions related to the topics discussed in
identifying hazards and determining controls. Answer all the questions after the picture.

1. A worker soldering in a dirty shop without ventilation and with no PPE.

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 Questions:
1) What is wrong with this picture? What is missing? How will this situation lead to this
worker being exposed to the lead used in the soldering process? Could this situation also
cause his family to be exposed to lead? How? What suggestions can you make to prevent
this situation?

Answer:
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2) A worker dry sweeping dust from soldering area.

Question: 
a) What is wrong with this picture?
Answer:
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 ______________________________________________________________________________
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3) A worker eating something I the work area.

Question:
a) What is wrong with this picture?
Answer:
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___________________________________________________________.

4) Picture shows shower and locker areas.

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 Question:
a) Why should employers provide shower and locker areas?
Answer:
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________________.

5) Pictures shows a worker wearing a cartridge respirator while working around

dusts.

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Answer:

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***(Note to Instructor: If you can get a cartridge respirator and a paper mask to show the
trainees, pass them around to show the difference, then explain as follows: one method of
preventing inhalation of hazardous substances is to use respirators, although this is not the best
method of prevention. A paper mask does not fit tightly against the face and will not prevent the
worker from inhaling gases, vapors or even dusts. A paper mask can be used
for  occasional exposure to non-toxic dust when the dust concentration is low. The cartridge
respirator is needed for working around gases or vapors but the type of cartridge you need to
use depends on the substances with which you are working.)

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 C. Checklist on Control Methods
Instructions: Students will be asked to observe a process/system/workplace and use the
following checklist to evaluate the hazards and controls that are implemented. After the
evaluation, students shall prepare report including their suggestion on how to address the
observed hazards in the workplace.

I. Machine Guards

When evaluating workplace for proper guarding, check for the following:

1. Are the operators' hands, fingers and bodies kept safely away from the danger areas when
a machine is being operated? If no, what type of guard could be installed?

☐Yes ☐ No
2. Are starting and stopping controls within easy reach of the operator?

☐ Yes ☐ No
3. Are belts, pulleys, chains, sprockets, gears and blades properly guarded?

☐ Yes ☐ No
4. Are rotating parts covered or out of reach inside the equipment?

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 ☐ Yes ☐ No
5. Are fans that are located near the floor guarded?

☐ Yes ☐ No
6. Are guards firmly attached so they cannot easily be removed?

☐ Yes ☐ No
7. Have operators been trained in the importance of using guards? Have they been trained in
the operation and maintenance of guarded machines?

☐ Yes ☐ No
8. If operators are not within sight or hearing distance of other workers, is an alarm device
provided in case of an accident?

☐ Yes ☐ No
9. Is there an effective system for disconnecting and locking out the machine from its power
sources when guards are removed during maintenance? Have workers been trained in
lockout procedures and in machine maintenance procedures?

☐ Yes ☐ No
10. Do machine guards restrict workers' productivity, cause discomfort or annoyance to the
operator?

☐ Yes ☐ No
11. Does the design or construction of the machine guards create any new dangers?

☐ Yes ☐ No
12. Is the company following all local or national requirements for machine guarding and any
special rules for guarding of hand and portable powered tools and laundry machinery?

☐ Yes ☐ No
II. Local exhaust ventilation

Use the following questions to help you when evaluating a local exhaust ventilation
system in a workplace.

1. Do you smell chemical odors or see dust building up near the hood or machines? Can
you see contaminants in the air?

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 ☐ Yes ☐ No
2. Is the hood close enough to the place where air contaminants are being released?

☐ Yes ☐ No
3. Are the ducts plugged? When you tap a duct, it should sound hollow; a “thud” may
mean it is plugged. Are filters clogged?

☐ Yes ☐ No

4. Are any ducts broken or leaking?

☐ Yes ☐ No
5. Check motors and fans. Are any belts broken? Are fans installed correctly (not
backwards)? Are fan blades covered with dirt, grease, etc. and inefficient?

☐ Yes ☐ No
6. Ask your employer to show you the original design of the system. Have extra hoods
been added to cover new machines? If any were added, was the system balanced
again? Can it handle the new load?

☐ Yes ☐ No
7. Are cross-draughts present that could carry contaminants away from the hood
opening? Could the operation be enclosed with shields or booths to prevent draughts?

☐ Yes ☐ No
8. Are there many bends, twists or Ys in the duct system? These can slow down the
movement of the exhaust air as well as causing increased noise levels.

☐ Yes ☐ No
9. Does the hood pull contaminants in the proper direction away from the worker's face
rather than past it?

☐ Yes ☐ No
10. Does the amount of clean air brought into the system equal the amount exhausted? If
you have trouble opening doors because of “negative pressure”, this may be an
indication that more fresh air is needed.

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 ☐ Yes ☐ No
11. Has the employer used an instrument called a velometer to see if the airflow is strong
enough?

☐ Yes ☐ No
12. To be sure the exhaust system is protecting workers, ask your employer to show you
monitoring measurements of the levels of chemicals or other hazardous materials in
the air. A ventilation system is only useful if it works and if it protects workers.

☐ Yes ☐ No
III. Personal Protective Equipment

Use the following questions when evaluating PPE if it must be used in your workplace.

1. Has all protective clothing (masks, helmets, gloves, eye protectors, overalls, boots,
aprons, etc.) been personally fitted and issued?

☐ Yes ☐ No
2. Are protective clothing items immediately replaced when damaged or lost?

☐ Yes ☐ No
3. Are protective clothing and equipment of good quality and the correct type for the job
being done? For example, are eye goggles the correct type for the hazards? Some only
offer protection against small flying particles, other types are required for protection
against large particles or acid splashes.

☐ Yes ☐ No
4. Are respirators handled carefully? Are masks personally fitted to ensure a proper seal? Is
the type of respirator correct for the conditions (e.g. dust filters do not protect against
gases or fumes; different canister and cartridge respirators are needed to neutralize
different vapors and gases in the air)? Is there an independent air supply — either air-line
or self-contained breathing apparatus for the most dangerous conditions? Have these been
thoroughly checked and maintained (a failure to do so could result in death)?

☐ Yes ☐ No
5. Have workers been properly trained in the use of PPE? Have workers and supervisors
been trained in the use of filter, canister and air-bottle systems (they are only effective for
limited periods of time)? Is the amount of time that workers are required to work in PPE
limited to short periods?

☐ Yes ☐ No

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 6. Is protective clothing (which can cause restrictive and oppressive working conditions)
only worn for limited periods of time? Are jobs rotated to enable wearing the PPE for
only short periods?

☐ Yes ☐ No
7. Is all PPE provided to workers free of charge?

☐ Yes ☐ No
8. Is PPE inspected, cleaned and maintained by management? Are workers expected to take
contaminated clothing home?

☐ Yes ☐ No
9. If the correct use of PPE affects bonus earnings, is the scheme altered to allow for this?

☐ Yes ☐ No
10. Does the use of PPE create other risks, e.g. by reducing vision, mobility or hearing?

☐ Yes ☐ No
11. Has the union been consulted about the purchase of PPE, and about setting up adequate
systems for fitting, issuing, testing, maintenance, cleaning, replacement, training and
supervision to ensure that equipment is effective?

☐ Yes ☐ No

IV. Glove or Respirator Program

Use these questions to help you when assessing a glove or respirator program.

1. Was the Glove or Respiratory Program communicated at all levels of the organization?

☐ Yes ☐ No
2. Does the organization provide any sampling results that the employer has on exposure
levels?

☐ Yes ☐ No
3. Is the organization is implemented or has plan to implement to remove chemicals from
the air or to prevent skin contact?

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 ☐ Yes ☐ No
4. Does the employer provide a written plan showing how the employer will reduce or
eliminate the need for wearing respirators or gloves in the future?

☐ Yes ☐ No
5. Does the organization assign a qualified person in charge of respirator and glove use?

☐ Yes ☐ No
6. What medical testing of workers will be done to ensure they are physically fit to work
wearing a respirator?

☐ Yes ☐ No
7. Is the medical testing not be used to discriminate against workers who are experiencing
lung problems caused by prior exposure to chemicals in the workplace?

☐ Yes ☐ No
8. Does the organization provide several different sizes or brands are made available, so
each worker can choose one that fits well?

☐ Yes ☐ No
9. Does the organization show the union any guidelines used for choosing the equipment?

☐ Yes ☐ No
10. Are respirators approved by recognized standard-setting institutions?

☐ Yes ☐ No
11. Is a union representative present at the training sessions for workers who will wear
protective gear?

☐ Yes ☐ No

V. General Cleanliness

Use this check-list when assessing cleanliness and order in the workplace.

1. Is the layout designed to facilitate order and cleanliness? Is there adequate space between
machines?

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 ☐ Yes ☐ No
2. Are aisles, passageways, transport areas and exits clearly marked and free of obstacles?

☐ Yes ☐ No
3. Are special areas set aside for storage of raw materials, finished products, tools and
accessories?

☐ Yes ☐ No
4. Are there racks for hand tools or other necessary items above work tables?

☐ Yes ☐ No
5. Are there under bench slots or other spaces for storage of small personal belongings?

☐ Yes ☐ No
6. Are receptacles for waste and debris in convenient locations?

☐ Yes ☐ No
7. Are floor-covering materials suitable for the work and for cleaning?

☐ Yes ☐ No
8. Are there screens or simple devices to prevent deposits of oil, liquid wastes or water on
the floors?

☐ Yes ☐ No
9. Are there drainage channels for waste water?

☐ Yes ☐ No
10. Are there special groups of people to carry out day-to-day cleaning and weekly or
monthly cleaning?

☐ Yes ☐ No
11. Have arrangements been made to remove finished goods and wastes?

☐ Yes ☐ No
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 12. Is there a clear assignment of duties for maintenance and repair of work premises,
particularly stairs, walkways, walls, lights and toilet/washing facilities?

☐ Yes ☐ No
VI. Personal Hygiene

To practice good hygiene, does the workers:

1. Drink clean drinking, potable water?

☐ Yes ☐ No
2. Never eat in locker rooms, washrooms or where dangerous materials are used?

☐ Yes ☐ No
3. Wash hands and the exposed parts of your body regularly and take daily baths or
showers?

☐ Yes ☐ No
4. Have periodic dental check-ups if possible?

☐ Yes ☐ No
5. Wear proper clothing and footwear?

☐ Yes ☐ No
6. Do not mix hazardous material with non-hazardous materials?

☐ Yes ☐ No
7. Wears clean working clothes, towels, etc. with the help of a special laundry, if possible,
particularly when they get contaminated?

☐ Yes ☐ No
8. Keep physically healthy by having regular/annual medical exam?

☐ Yes ☐ No
VII. First-Aid and Fire-Fighting Equipment

Use this check-list to help you assess the first-aid and fire-fighting equipment in your
workplace.

1. Is adequate first-aid equipment provided and checked regularly?

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 ☐ Yes ☐ No
2. Are trained and adequate first-aid personnel present during all shifts?

☐ Yes ☐ No
3. Is adequate fire-fighting equipment provided?

☐ Yes ☐ No
4. Is fire-fighting equipment maintained in a usable condition?

☐ Yes ☐ No
5. Are locations of fire-fighting equipment posted?

☐ Yes ☐ No
6. Have workers been trained in the use of fire-extinguishing equipment?

☐ Yes ☐ No
7. Are emergency telephone numbers posted?

☐ Yes ☐ No

VIII. Methods of Control

Use this check-list to help you evaluate the methods of control in your workplace. Before
being satisfied with any methods of control, ask yourself the following questions:
1. Does it adequately control the hazard?

☐ Yes ☐ No
2. Does it allow workers to do their job comfortably without creating new hazards?

☐ Yes ☐ No
3. Does it protect every worker who may be at risk of exposure to the hazard?

☐ Yes ☐ No
4. Does it eliminate the hazard from the general environment as well as the workplace?

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 ☐ Yes ☐ No
5. Are less toxic chemicals used whenever possible?

☐ Yes ☐ No
6. Are work processes used which minimize the release of gases, vapors, dusts or fumes?

☐ Yes ☐ No
7. Are the sources of the release of gases or vapors completely enclosed?

☐ Yes ☐ No
8. Are dust-producing machines or piles of dusty materials isolated or enclosed as much as
possible?

☐ Yes ☐ No
9. Are workstation locations chosen so that exposure to gases, vapors, dusts or fumes is
minimal?

☐ Yes ☐ No
IX. Labelling, Information and Emergency Measures

Use this check-list to help you assess whether chemical labels, information and
emergency measures are adequate.

1. Are containers with chemicals in them labelled indicating the contents and warning of
the hazard?

☐ Yes No
2. Is necessary information on safe handling and first-aid measures given on the label or
as written instructions?

☐ Yes No

3. Have workers been trained on health risks and safe handling of hazardous chemicals?

☐ Yes No

4. Does training include information on safe storage and transportation of chemicals?

☐ Yes No

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 5. Are emergency showers and eye-wash stations available at the worksite?

☐ Yes No

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