INTROUCTION: We carry out risk assessment in the truck tire building department of GENERAL TYRE AND RUBBER COMPANY

OF PAKISTAN. This risk assessment is performed in accordance with the systematic procedure for describing and quantifying the risks associated with, Hazardous substance Process Action or Event

Identification of hazard associated with task or activity was our first objective. One way of doing this is by using PEME i.e. identifying risks associated with people, equipment, materials and environment. The next step was to identify that that can get harm by these hazards. Then we identified that whether there were any control measures or not. Table A defines the risk levels (high, moderate and low) adopted to classify risks to the truck tire building department. Table A: Risk Classifications
Risk Level High Risk Description The lack of supervision, communication, repair and maintenance could be expected to have a severe or catastrophic adverse effect on productivity, operations, or individuals. The lack of supervision, communication, repair and maintenance could be expected to have a serious adverse effect on productivity, operations, or individuals. The lack of supervision, communication, repair and maintenance could be expected to have a limited adverse effect on productivity, operations, or individuals.

Moderate

Low

Risk assessment involves measuring the probability that a risk will become a reality; impact analysis involves measuring the sensitivity of the project to each identified risk. The key questions are:

What is the risk how will I recognize it if it becomes a reality? What is the probability of it happening high, medium or low? How serious a threat does it pose to the project high, medium or low? What are the signals or triggers that we should be looking out for?

RISK IDENTIFICATION: The purpose of this step is to identify the risks to truck tire building department. Risks occur in the department when vulnerabilities (i.e., flaws or weaknesses) in the department or its environment can be exploited by threats (i.e. natural, human, or environmental factors). The process of risk identification consists of three components: 1. Identification of vulnerabilities in the department and its environment; 2. Identification of credible threats that could affect the department; and 3. Pairing of vulnerabilities with credible threats to identify risks to which the department is exposed. Table B defines the vulnerabilities, threats and risks for truck tire building department.

Risk No.

Vulnerability

Threat

Risk of compromise of Workers health and safety

Risk Summary

Job requires lifting heavy material (loading and unloading tires)

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Back sprains, muscle pulls, wrist injuries, elbow injuries, spinal injuries, and other injuries caused by lifting heavy material.

Presence of fire hazardous material (benzene and rubber) Recurrence of repair and maintenance

Fire

Downtime

All these injuries can result in occupational fatigue. Such injuries would account for one third of all lost work and even more than one third of all compensation costs. More important than financial cost is human suffering. Safe working Fire would cause a environment and lot of damage to companys human as well as integrity in case the working area. of any accident. Production time Any repair work the maintenance department does to equipment will result in downtime, will take away time from production and will cost money.
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Risk No.

Vulnerability

Threat

Risk of compromise of

Risk Summary

Shortage of material from the previous department

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Slower production

Negligence of front line management staff

Difficulty in achieving daily production targets

Running band over the drum

Running band over a drum produces a great deal of pressure on the back bone / spine of worker

Employee morale When employees are unable to work and companys because of material good will. shortage they will get less salary which will result in reduce morale. Moreover, the company will also suffer in case of unfilled orders and dissatisfied customer. Difficulty in Quantity and achieving daily quality of product production targets will result in unfilled orders, dissatisfied customer and poor quality of product. Little error in Workers health running band over and safety a drum may cause band bar hit the drum that will result in serious accident. In case of any accident both worker and the people nearby could be injured.

CONTROL ANALYSIS: The purpose of this step is to document a list of controls used for the truck tire building department. These controls should correspond to the requirements of the Policy, Standard, and Audit Standard. The analysis should also specify whether the control is in-place (i.e., current) or planned, and whether the control is currently enforced. In the next step these controls are matched with the risks identified in order to identify those risks that require additional response. Associate the risks with the relevant controls in a Risks-Controls table as below. This correlation determines whether controls exist that respond adequately to the identified risks. Indicate where controls are not in place or where they appear not to have been implemented effectively.
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Risk No.

Risk Summary All these injuries can result in occupational fatigue. Such injuries would account for one third of all lost work and even more than one third of all compensation costs. More important than financial cost is human suffering.

Correlation of Relevant Controls

Under regulation 3.1(a) of the OSH Regulations, a person who, at a workplace, is an employer, the main contractor, a self-employed person, a person having control of the workplace or a person having control of access to the workplace must, as far as practicable, identify each hazard to which a person at the workplace is likely to be exposed. More specifically, regulation 3.4(2)(a) of the OSH Regulations requires that an employer, the main contractor, or a self-employed person must, as far as practicable, identify each hazard that is likely to arise from manual handling at the workplace. This includes the identification of manual handling tasks that may give rise to injuries or harm or those where employees have identified concerns. The regulatory reform (FIRE SAFETY) order 2005 sets out the law on construction site general fire safety. The FSO requires that a responsible person must carry out, and keep up to date, a risk assessment and implement appropriate measures to minimize the risk to life and property from fire. The responsible person will usually be the main or principal contractor in control of the site. 1910.37(d)(2) During repairs or alterations, employees must not occupy a workplace unless the exit routes required by this subpart are available and existing fire protections are maintained, or until alternate fire protection is furnished that provides an equivalent level of safety.

Fire would cause a lot of damage to human as well as the working area.

Any repair work the maintenance department does to equipment will result in downtime, will take away time from production and will cost money.

According to the European Standard EN 13306, maintenance concerns the "combination of all technical, administrative and managerial actions during the life cycle of an item intended to retain it in, or restore it to, a state in which it can perform the required Lack of maintenance or inadequate maintenance can cause serious and deadly accidents or health problems.

When employees are unable to work because of material shortage they will get less salary which will result in reduce morale. Moreover, the company will also suffer in case of unfilled orders and dissatisfied customer. Difficulty in achieving daily production targets will result in unfilled orders, dissatisfied customer and poor quality of product. Running band over the drum

The Occupational Health and Safety Code of Practice should not only be followed by employers, but it should be posted for employees to see, so they understand their basic rights. Employers who do not follow the contents of the code of practice can be cited by an OSHA investigator and face financial penalties, or even be closed down depending on the serious of the penalty.

OSHA safety practitioners international entails a duty to serve and protect people, property and environment. This duty is to be exercised with integrity and honor.

You have the right to a safe workplace. The Occupational Safety and Health Act of 1970 (OSH Act) was passed to prevent workers from being killed or seriously harmed at work. The law requires employers to provide their employees with working conditions that are free of known dangers. The Act created the Occupational Safety and Health Administration (OSHA), which sets and enforces protective workplace safety and health standards. OSHA also provides information, training and assistance to workers and employers. Workers may file a complaint to have OSHA inspect their workplace if they believe that their employer is not following OSHA standards or that there are serious hazards.

RISK LIKELIHOOD DETERMINATION: The purpose of this step is to assign a likelihood rating of high, moderate or low to each risk identified in Table D. This rating is a subjective judgment based on the likelihood vulnerability might be exploited by a credible threat. The following factors should be considered: Threat-source motivation and capability, in the case of human threats; Probability of the threat occurring, based on statistical data or previous experience, in the case of natural and environmental threats; and Existence and effectiveness of current or planned controls

Risk Likelihood Ratings

Risk No. Risk Summary Risk Likelihood Evaluation Risk Likelihood Rating

All these injuries can result in occupational fatigue. Such injuries would account for one third of all lost work and even more than one third of all compensation costs. More important than financial cost is human suffering. Fire would cause a lot of damage to human as well as the working area.

There are no controls for this problem, so the effectiveness of control is low. Threat source capability and motivation is high as lifting heavy material is an important part of the job.

HIGH

Effectiveness of control to prevent fire is high. Usage of cigarette, lighter and matchstick is strictly prohibited in the department. Threat source motivation is high as the involvement of fire hazardous material cannot be avoided. No controls are in place to avoid the recurrence of repair and maintenance work, so control effectiveness is low. Threat source motivation is rated as moderate because the risk is dependent on the occurrence of maintenance work; sometimes the occurrence is high and sometimes it is low. There are no controls for this problem so the effectiveness of controls

HIGH

Any repair work the maintenance department does to equipment will result in downtime, will take away time from production and will cost money

MODERATE

When employees are unable to work because of

MODERATE

material shortage they will get less salary which will result in reduce morale. Moreover, the company will also suffer in case of unfilled orders and dissatisfied customer.
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is low. Threat source capability is moderate as only the previous department is responsible for this vulnerability. It can be avoided through proper supervision.

Difficulty in achieving daily production targets will result in unfilled orders, dissatisfied customer and poor quality of product.

Effectiveness of controls that ensure a smooth production is sufficiently low. Threat source motivation is rated high as the negligence of front line management staff is a very crucial problem and has to be taken very seriously There are no controls for this problem. Threat source motivation is high.

HIGH

Running band over the drum

HIGH

RISK IMPACT ANALYSIS: The purpose of this step is to assign an impact rating of high, moderate or low to each risk identified in the previous table. The impact rating is determined based on the severity of the adverse impact that would result from an occurrence of the risk.

Risk Impact Analysis

Risk No. Risk Summary Risk Impact Risk Impact Rating

All these injuries can result in occupational fatigue. Such injuries would account for one third of all lost work and even more than one third of all compensation costs. More important than financial cost is human suffering. Fire would cause a lot of damage to human as well as the working area. Any repair work the maintenance department does to equipment will result in downtime, will take away time from production and will cost money. When employees are unable to work because of material shortage they will get less salary which will result in reduce morale. Moreover, the company will also suffer in case of unfilled orders and dissatisfied customer. Difficulty in achieving daily production targets will result in unfilled orders, dissatisfied customer and poor quality of product. Running band over the drum

Non availability of workers, loss of production time, loss of time and resources of the safety staff

HIGH

Damage to machines and other material, human life at stake, companys reputation at stake Loss of time and resources

HIGH

HIGH

Unfilled orders, dissatisfied customer, reduce morale of workers

HIGH

Production suffers, less profit, companys good will at stake

HIGH

It can result in very serious accident; even death can occur

HIGH

OVERALL RISK DETERMINATION: The purpose of this step is to calculate an overall risk rating of high, moderate or low for each risk identified in the table. The determination of risk ratings is somewhat subjective.

Risk impact
Risk likelihood High (1.0)

Low (10) Low 10 x 1.0 = 10 Low 10 x 0.5 = 5 Low 10 x 0.1 = 1

Moderate (50) Moderate 50 x 1.0 = 50 Moderate 50 x 0.5 = 25 Low 50 x 0.1 = 5

High (100) High 100 x 1.0 = 100 Moderate 100 x 0.5 = 50

Moderate (0.5)

Low 100 x 0.1 = 10 Risk Scale: Low (1 to 10); Moderate (>10 to 50); High (>50 to 100)

Low (0.1)

Overall Risk Ratings Table

Risk No. Risk Summary Risk Likelihood Rating Risk Impact Rating Overall Risk Rating

All these injuries can result in occupational fatigue. Such injuries would account for one third of all lost work and even more than one third of all compensation costs. More important than financial cost is human suffering. Fire would cause a lot of damage to human as well as the working area. Any repair work the maintenance department does to equipment will result in downtime, will take away time from production and will cost money. When employees are unable to work because of material shortage they will get less salary which will result in reduce morale. Moreover, the company will also suffer in case of unfilled orders and dissatisfied customer.

HIGH

HIGH

HIGH

HIGH

HIGH

HIGH

MODERATE

HIGH

MODERATE

MODERATE

HIGH

MODERATE

Risk No.

Risk Summary

Risk Likelihood Rating

Risk Impact Rating

Overall Risk Rating

Difficulty in achieving daily production targets will result in unfilled orders, dissatisfied customer and poor quality of product. Running band over the drum

HIGH

HIGH

HIGH

HIGH

HIGH

HIGH

RECOMMENDATIONS The purpose of this step is to recommend additional actions required to respond to the identified risks, as appropriate to the departments operations. The goal of the recommended risk response is to reduce the residual risk to the system and its data to an acceptable level. Recommendations
Risk No. Risk Summary Risk Rating Recommendations

All these injuries can result in occupational fatigue. Such injuries would account for one third of all lost work and even more than one third of all compensation costs. More important than financial cost is human suffering.

HIGH

Training is not the most important method of preventing manual tasks injuries and you should not rely upon training in the absence of modifying the task or even eliminating manual tasks whenever possible i.e. always consider a design option as your first option for control. However, training is a key element of an employer's legal obligation to provide a healthy and safe workplace.

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Fire would cause a lot of damage to human as well as the working area.
2

HIGH

Any repair work the maintenance department does to equipment will result in downtime, will take away time from production and will cost money.

MODERATE

Early detection of fire and early warning to staff and guests to facilitate an adequate response. Limitation of development and spread of fire. Early suppression of fire where possible. A step towards preventive maintenance can be helpful in this case. Preventive maintenance covers all programmed maintenance which is carried out in order to prevent the occurrence of failures before they develop to a breakdown or interruption in production. Proper stocking of material should be ensured in the stock building department.

When employees are unable to work because of material shortage they will get less salary which will result in reduce morale. Moreover, the company will also suffer in case of unfilled orders and dissatisfied customer. Difficulty in achieving daily production targets will result in unfilled orders, dissatisfied customer and poor quality of product.

MODERATE

HIGH

The production manager must plan and control the process of production so that it moves smoothly at the required level of output while meeting cost and quality objectives. Process control has two purposes: first, to ensure that operations are performed according to plan, and second, to continuously
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monitor and evaluate the production plan to see if modifications can be devised to better meet cost, quality, delivery, flexibility, or other objectives. 6 Running band over the drum HIGH Qualified and trained workers should be deputed in this section

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