KPI Cargo Dock

WTS December 23, 2016

08:20 – 10: 00
Area Owner : KPI
Assessor : Mr. Joko Wibowo and Dr. Alexandra Irene.
Escorted by : Mr. Rusli, Mr. Iwan Setiawan, and Mr. Melkior.

Preface
Walk through Survey (WTS) is a visiting program of an occupational health doctor and
Industrial Hygiene practitioner in several PT FI location where a health problems from working
activity or material used in work is identified.
As scheduled, this Walk Through Survey was arranged by the Industrial Hygiene Team, and so,
on Friday, December 23rd 2016, the survey was done in the KPI Heavy Duty Shop area, Cargo
Dock.
A few days before the survey, the Industrial Hygiene Team has contacted and coordinated with
the person in charge for these areas regarding this visiting plan, and has already requested the
person in charge to accompany the WTS team while doing the survey.

General Information :
Location’s Name : KPI Heavy Duty Shop, Cargo Dock Area.
Escorted by : Mr. Rusli, Mr. Iwan Setiawan, and Mr. Melkior.

Working Hours :
The staffs in KPI Heavy Duty Shop works in two shifts ;
Day Shift : from 06:00 am to 17:00 pm, and,
Night Shift : from 17:00 pm to 06:00 am.
The shifts area a 6 days working days and 1 day off, with shift changes after off days.
There are a total of 40 crews working in the KPI Heavy Duty Shop, some of them are permanent
workers and the others are from contractors.
These men are working on the previously explained two shifts. The permanent workers are from
the KPI Marine Operations, while the contractor in the KPI Heavy Duty Shop are Cakra Jawara
Company, Trakindo, Saraghani and Intecs. The Cakra Jawara Company is responsible on the
repair of all machineries from IVECO, - they are the only one who hold the license for manual
repair of IVECO machineries.

Activity Flow / Production Flow

The KPI Heavy Duty Shop is a place of heavy machinery reparation. Main job of the shop is to
repair different kinds of heavy machinery from the operational machines used in the cargo dock
area.
Listed below are the machines repaired in the KPI Heavy Duty Shop :

SAP EQUIP NO EQUIP DESCRIPTION

600000221966 MANITOWOC TRACK CRANE 14000 SERIES II
600000222039 CAT BACKHOE 428E
600000222217 LINCOLN DIESEL WELDING MACHINE 400AS
600000221764 TEREX SUPER STACKER TFC45HC
600000952622 TEREX SUPER STACKER TFC45HC
600000221758 KALMAR FORKLIFT DCF370-12
600000221782 KALMAR TIRE HANDLER DCF330-12
600000221455 CAT WHEEL LOADER FORKLIFT 966G
600000221461 CAT WHEEL LOADER FORKLIFT 966H
600000221494 CAT WHEEL LOADER FORKLIFT 966H
600000953127 CAT WHEEL LOADER QUICK COUPLER 966H
600000221454 CAT WHEEL LOADER 966G
600000221751 CAT WHEEL LOADER 966G
600000221767 CAT FORKLIFT DP50N
600000222811 CAT GENSET (164KW-3PH-240V-60HZ)
600000223086 CAT GENSET (180KW-3PH-380/220V-50HZ)
600000222896 CAT GENSET (180KW-3PH-380/220V-50HZ)
CAT GENSET (180KW-3PH-380/220V-50HZ)
CAT GENSET (180KW-3PH-380/220V-50HZ)
600000221072 IVECO TRACTOR 6X4
600000221073 IVECO TRACTOR 6X4
600000221133 IVECO TRACTOR 6X4
600000221134 IVECO TRACTOR 6X4
600000221219 IVECO TRACTOR 6X5
600000221222 IVECO TRACTOR 6X7
600000221223 IVECO TRACTOR 6X8
600000221218 IVECO TRACTOR 6X8
600000954976 IVECO WATER TRUCK AD380T38W 6X4
 STINIS AUTOMATIC CONTAINER SPREADER
600000224249
20FT
STINIS AUTOMATIC CONTAINER SPREADER
600000955161
20FT
STINIS AUTOMATIC CONTAINER SPREADER
600000961616
20FT
STINIS AUTOMATIC CONTAINER SPREADER
600000961617
20FT
STINIS AUTOMATIC CONTAINER SPREADER
600000961618
20FT
STINIS AUTOMATIC CONTAINER SPREADER
20FT
600000221849 INGERSOLL RAND AIR COMPRESSOR 7100
600000223403 PORTER HIGHLAND CARGO TRAILER
600000223440 SSB REAR CARGO TRAILER
600000223466 SSB FLAT TOP SINGLE TRAILER
600000223467 SSB FLAT TOP SINGLE TRAILER
600000223468 SSB FLAT TOP SINGLE TRAILER
600000223540 SSB REAR CARGO TRAILER
600000223441 SSB FRONT CARGO TRAILER
600000961637 LINCOLN DIESEL WELDING MACHINE AV500
600000220193 IVECO DAILY S17DW 4X4 LB
600000225187 CAT WHEEL LOADER 966G
600000966211 SSB DROP DECK TRAILER 50T
600000966212 SSB DROP DECK TRAILER 50T
600000966213 SSB DROP DECK TRAILER 50T
600000966214 SSB DROP DECK TRAILER 50T
600000966215 SSB DROP DECK TRAILER 50T
600000966216 SSB DROP DECK TRAILER 50T
CAT TRACK EXCAVATOR 336D2L
CAT TRACK DOZER D10T
CAT TRACK DOZER D10T
CAT WHEEL LOADER 988H

CAT WHEEL LOADER 988H

CAT WHEEL LOADER 988H

CAT WHEEL LOADER 988H

CAT WHEEL LOADER 988H

CAT WHEEL LOADER 966H
 CAT WHEEL LOADER 966H
CAT WHEEL LOADER 966H
CAT WHEEL LOADER QUICK COUPLER 966H
CAT WHEEL LOADER 966H
CAT WHEEL LOADER 966H
CAT WHEEL LOADER FORKLIFT 988H
WS DUMP TRUCK 6X4 40T (AV)
WS DUMP TRUCK 6X4 40T (AV)
JLG MANLIFT 660SJ
MANITOWOC TRACK CRANE 14000 SERIES II
SUPER STACKER FORKLIFT TEREX TFC-45H
GROVES MOBILE CRANE RT530E-2
GROVES MOBILE CRANE RT650E-2

The main activities in the KPI Heavy Duty Shop includes mechanic works, repairing works,
electrician, lubrications, welding, and cleaning the machineries.
The work of heavy duty repair require the workers to stay in many different positions while
doing their work. Some has to lay on the ground with both arms lifted to fix a truck / bus (slide
under the truck), some other has to do pumping movements on the pipelines, and some other has
to squat / sit for some times doing welding. These make it difficult to maintain an ergonomic
body posture during work, - and may be a risk factors for work related musculoskeletal
problems.

Jobs
Major Categories :
a. Mechanic
b. Electrician
c. Welder
Supporting Jobs :
a. Cleaning jobs.
Crews
There are a total of 40 crews working in the KPI Heavy Duty Shop with 4 – 5 crews working on
each shift (only from the permanent crews)
Supervisor :
General Foreman :
Foreman :

Exposure
Since the KPI Heavy Duty Shop is located in the Cargo Dock area, it is well exposed to sea air,
weather, and dust from the operational movements.
The compressor machine and most of the tools used caused a lot of noise with measured 70 – 90
dB. The workers are exposed to the noise on daily basis, - 12 hours a day. Aside from noise and
dust, the workers are also exposed to heat, - caused by weather heat and heat produced from the
machines and equipment used. Other possible exposure are chemical exposure to grease, oil, and
chemical substances used to repair the machines.

Exposure found in the KPI Heavy Duty Shop are :

 Heat; - Heat exposure from the welding machine, truck machine, electrical panel and
from the original weather (since the shop is located on the shoreline area).
 Noise; - Most of the noise come from the compressor device and from the truck/loader/
any machineries that is currently being repair, - since the engine has to be started
repeatedly to check.
 Dust; - Exposure to dust is mainly caused by the sandy origin of the land, and the
machine used. The shop is also an open building, - making dust exposure inside the shop
area.
 Chemical substances; -All of the workers inside the shop have chances of exposure to
chemical substances since the job includes refilling coolant fluids for truck and bus
engines, and is using grease and oil as lubricants for the machines.
 Manual Handling; - A lot of workers inside the shop (mainly mechanics) will be
exposed to manual handling in terms of working with awkward positions (lying below a
truck / bus), pumping the hydraulic system of a head cabin (half – bending position),
fixing low height machines (squatting / kneeling for a long term).
 Possibility of injuries from many tools scattered on the shop floor. Every workers are
equipped with their own toolboxes, and while working, each worker is responsible for
their own toolbox. However, while repairing different area of a machine, - say a truck for
example, each workers will put the toolbox nearby, and sometimes putting other tools
 like, a ladder, a bucket, etc. This may cause possibility of accident when other workers
walk by and trip over the scattered tools on the floor.

Health and Safety Issue in the Working Area.

The personal protective equipment (PPE) required in the KPI Heavy Duty Shop Area are :
 Safety glasses
 Helmet
 Gloves (different specification for different uses).
o PVC gloves (red) for handling grease and chemical uses
o Clothing gloves for handling iron and machines.
 Ear plugs
 Safety shoes (all workers and visitors)
 Respiratory masks (different specification for different uses)
o Normal masks (white) for working with dust exposures (cleaning etc)
o Respirator for working with lot of dust exposures and chemical dust exposures.
Several Boards for PPE uses already put on the walls of the shop to remind the workers and
visitors to wear all the PPE required in this area.
Dust exposure in the area is caused by the equipment used and the origin of the shop that is
located near the shoreline. It should be advised for all workers to keep on using the appropriate
respiratory masks, depends on the works they are doing. Any cleaning duties are all related to
dusts and therefore the workers should at least use the normal respiratory masks. If the cleaning
is related to chemical material and dangerous particles like silica, all workers should be using the
respirator to prevent or reduce the inhalation of the particles that may cause inflammation of the
lungs, - like silicosis and other related conditions. Symptoms like cough, fever, and shortness of
breaths may resemble upper respiratory tract infection or even lower respiratory tract infections
related to exposure of dust / microorganism / inhalation of dangerous particles. In these kind of
environment, there is a possibility of progressive lung diseases from long term exposure to the
dust particles.
Noise induced Hearing Loss (NIHL), may be caused by a long term exposure of noise with
threshold above 85 dB in at least 8 hours exposure per day. Workers who are not using any ear
protection devices in the area may suffered from NIHL after some time working. Aside from the
ear protections, if possible, a modification on the machines and devices can be done to reduce the
noise produced by the machines.
Manual handling, should be done with ergonomic principles when working. This is to avoid any
work related injuries and incidents.
Work related – musculoskeletal disorders is by now among the top ten of the work related
condition / diseases. A long – term posture hold when working may cause disturbances on the
musculoskeletal system. In the KPI Heavy Duty Shop, there are some works that needs to be
done with awkward postures, maintaining body posture for a long time, and body movements /
maneuver that may cause musculoskeletal disorders, mainly on the spine and on the main joints /
articulations. This should be avoided because some of the work related musculoskeletal disorders
may cause permanent damage to the workers.
During the visit, some of the examples found were:
 The welders, - who have to kneel / squat in a certain position for quite a long time while
doing welding.
 The repairmen, - workers fixing heavy duty machineries/ bus / truck have to stand in a
hole below the trucks with both their arms above shoulder level while fixing the
machines.
 The repairmen, - workers fixing heavy duty machineries / truck sometimes have to lay
below a machine in order to fix low – laying devices.
 The repairmen / cleaners, - have to do manual pumping / hydraulic of the head cabin of
the trucks, - this is done with a half standing position that require them to bear the body
weight on both legs while half bending and doing repetitive movements of pumping.
This, in a long term, may cause a progressive injury on the upper and lower back muscles
area.
Heat / Temperature in the KPI Heavy Duty Shop is also considered a health issue due to the high
temperature and humidity in the area, - since it is originally located near the shoreline. Aside
from the normal temperature on the shore area, heat is also produced by a huge electrical panel
located in the KPI Heavy Duty Shop, and also produced by most of the machineries, and the
devices used to fix the machines (like welding devices, etc). Related to this condition, it should
be put to mind to maintain the focus of the workers by at least making sure that they are well
hydrated all the time. This is to avoid further disturbance / danger that may happen like the lack
of focus while working that may cause accidents.

Public Facility on the Working Area

 Lack of rest and dining area on the working area.
 Limited garbage bin on the area
 Limited place to refill drinks on the area.

Findings during visit

There are several findings that may need further attention during this WTS visit;

 The condition of the main building (especially on the roof area), that has been
dented and corrosive in many parts. This may cause danger, - like damage on the roof
area that may fall down and hurt the workers.
  Main electrical panel is located near the storage of flammable liquids. This may
cause flammable / explosion danger due to the heat caused by the electrical panel that
may trigger fire.
 Lack of board signs indicating the requirement of PPE uses in the area, - especially for
different type of breathing masks and gloves. While these two items are used in daily
basis by a lot of worker in the KPI Heavy Duty Shop.
 In the outside of the Shop, there are a lot of wet area with water and mud that may cause
danger from slip and fall. There is also a big pipe used to pump water outside (due to the
previous incident of water flooding the shop area).
 Inside the Shop area, there are a lot of tools put on the floor by each workers nearby.
These tools are undoubtedly used by the workers in time, but if not being careful, these
may cause a risk of falling – when walking inside the shop.
 There were several workers working (fixing a truck unit) and was handling chemical
compound, - like grease. The workers were wearing the correct gloves but were using T –
shirts and with short sleeves. So there are some area of the arm skin exposed. While
working beneath a truck unit, the workers will need to maintain a posture of both arms
above the shoulders for a long time. These may result in danger of chemical exposure to
the exposed skin.
 Lack of drinking water supply in the area, - so that the workers will have to walk in order
to refill their drinking water. This will cause the workers to be lazy to walk and get the
water, and when they are not well hydrated, they may lose focus and will be dangerous in
the place with this heat.
 Lack of signs near the chemical compound – to wear protective gloves according to the
chemical compound handled.
 Lack of garbage / dustbin on the working area. Only one site of normal dustbin found on
the outside of the shop.
 Dusty environment on all area of the Shop, recommending all workers and visitors to
wear respiratory masks at all times, - and even more, workers, to wear appropriate
respiratory masks depending on the work they are currently doing.

Post Survey Recommendations

 Advise on re – listing all the 40 staffs names on the list to be sent to MCU for coding
and adjustment for yearly MCU.
 Regular socialization on the use of PPE to all workers in the area, with penalty to those
who are not using them.
 Coordination with related department regarding the building condition and advise on any
necessary repairs especially on the roof area, to reduce any risks of danger caused by the
building condition.
 Coordination with related department regarding the building basic condition (location of
electrical panels near the flammable liquid area). This should be done in near future to
 avoid any risk of fire due to the heat produced by the electrical panels. A thermal scanner
may be advised to be used to first evaluate / measure the heat on the electrical panels.
 Coordination with related department to do engineering modification on any device that
produce a lot of dusts and worsen the already bad air quality in the working area.
 Additional safety boards on areas with high caution (such as the area with hot working
permit, flooded area, and area of chemical liquids).
 Advised to coordinate with related department regarding the building location and
arrangement that caused it to be flooded with sea water several times.
 Work together with Industrial Hygiene PTFI for measurement of air quality and thermal
measurement on the working area, and also noise measurement every year in this area.
 Maximizing the clean up function, like routine cleaning of the devices used, and to have a
special worker for cleaning in the working area.
 Advise and recommendation for the workers to work with ergonomic position to avoid
further work – related musculoskeletal disorders.
 To do inspection and handling regularly for all equipments used according to the standard
operational procedure.
 Provide facility for food and drinking water nearby the working area so the workers are
ensured to have enough hydration and rest in order to keep focus.
 Provide appropriate garbage bin / dust bin (more) in the area.
 To give recommendations for related department / PHMC to routinely check the quality
of drinking water and put on signs for any water that is safe to drink.
 To clean any water splash / flood on the floor area and keep the floor area as tidy and
empty as possible (not putting unused stuffs on the floor) to avoid accident from falling
down / trip over something.

Images from survey