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SAFETY AND RISK EVALUATION IMPLEMENTATION AT SHEET METAL STAMPING INDUSTRY USING HIRARC MODEL

NUR SYUHAIDA BINTI HUSSAIN (2014682758)

A thesis submitted in partial fulfillment of the requirements for the award of Bachelor of Mechanical Engineering (Manufacturing) (Honours)

Faculty of Mechanical Engineering UNIVERSITI TEKNOLOGI MARA (UiTM)

JULY 2017

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ACKNOWLEDGEMENT

‘In the name o f Allah (God), The Most Compassionate, The Most M erciful’

All praise is Dua to Allah, the Lord of the World, for His mercy and blessing that enables me to accomplish this project. Salawat and Salam are rendered to the Prophet Muhammad SAW and his family.

I would like to thank my lecturer and supervisor, of the Faculty of Mechanical Engineering at University Technology MARA (UiTM) Cawangan Pulau Pinang. She consistently allowed this paper to be my own work, but steered me in the right direction whenever she thought I needed it

I am also grateful to my Co-supervisor and also the Assistant Manager of Production at AEL Engineering Sdn. Bhd. Parit Buntar for helping me in handling the tools, the company performances and equipment in the factory also offering me to give a better plan for the company’s long term performances on safety.

I must express my very profound gratitude to my parents, also, my family for providing me with unfailing support and continuous encouragement throughout my years of study and during my project periods.

Finally, I would like to thank all my friends and classmates for the help and moral support that was given for the accomplishment of this project.

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ABSTRACT

Sheet metal stamping has been identified as one of the most hazardous and high risk process in the world of manufacturing industries. In the competitive and unsteady economic situation, it is a challenging task for manufacturing industry to face it. This project was carried out at AEL Engineering Sdn. Bhd. in Parit Buntar, Perak. The company is a precision metal stamping supplier of metal components and assemblies. Their metal stamping presses sizes range from 5 tons to 800 tons. This project is focused on 200 tons and 150 tons departments only. A systematic analysis based on Occupational Safety and Health (OSHA) standard was used to create a model of Hazard Identification, Risk Assessment and Control (HIRARC) at the stamping department. The tools of HIRARC process were used to determine hazardous process / areas for department operation and maintenance of observation, safety analysis, workplace inspection, safety checklist and high risk investigation.

Initial risk assessment was conducted by classifying the hazards in three types of level, such as High, Medium and Low. The severity of hazards was calculated to estimate the likelihood it will happen and to decide which process/area needs to be applied control measures. The recommended control measures were implemented in the departments followed by administrative and engineering measures. The risk assessments were repeated and the results were analyzed. From the analysis of risk assessment for a total of eight hazardous processes/areas, shows that a reduction of

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TABLE OF CONTENTS

CONTENTS PAGE

PAGE TITLE i

ACKNOWLEDGEMENT ii

ABSTRACT iii

TABLE OF CONTENTS iv

LIST OF TABLES xi

LIST OF FIGURES xiii

LIST OF ABBREVIATIONS xvii

CHAPTER ONE INTRODUCTION

1.1 Background of Project 1 1.1.1 Company Background 2

iv

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CHAPTER ONE

INTRODUCTION

1.1 Background of Project

The manufacturing industry is one of the major sectors that help in the growth of the economy in Malaysia as shown in Figure 1.1. Productivity growth and overall performances are important aspects of a company to prosper. The company’s performances are affected by problems such as the work distance traveled, machine handling, workers’ behavior and the safety level of the department [8,9]. Therefore, this study will look into how safety management for the working layout can improve the process, resources, and energy efficiency with the aim to improve the production system performances

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