Question

 

CASE STUDY

In the Appliances Manufacturing Plant, a large number of engineering activities are carried out in a wide range of areas. These activities include design, production of parts, assembly, testing, and quality assurance.

Many of the manufacturing processes in the plant are performed using automated technologies and equipment. People also perform some of the manufacturing tasks and the plant employs over 400 workers. The decision on whether people or machines will be used for a particular task is dependent on many factors, including costs, time, quality and worker health and safety.

The plant considered here produces a many part for appliances and assembles them. Among the parts produced are door and housing materials and parts, compressors, motors, fans, some exterior parts, and electronics components. The plant normally operates three shifts per day and has production lines including machining equipment, conveyers and overhead cranes, punch presses, and paint-spray booths. The plant utilizes electricity and natural gas extensively.

A number of workers at the plant have over the last six months been subject to several different health problems. The following information has been received by the head engineer at the plant.

The head engineer at the plant wants to ensure that the plant provides a safe and healthy environment. So, she decides to ask an engineering health and safety consulting company to do a health and safety audit of the plant. The report provided by the consulting company lists the following safety problems:

a)     An expert on fires and explosions notes that the extensive use of natural gas in the plant could lead to an explosion in the plant in some circumstances. The force of such an explosion could lead to severe injuries or deaths of workers and, possibly, cause the building to be damaged or to collapse. The potential for an explosion could develop if a sufficient natural gas leak occurs or the plant ventilation system fails to perform properly or certain controls or sensors fail. But, the expert further notes, there is insufficient

         information available on the concentration of natural gas in the plant air, as only one natural gas sensor is in place at the plant, but it is not located in the main area where an accumulation of natural gas is likely to occur. Thus, the potential for an explosion could exist, yet not be detected or acted upon. In addition, the expert is concerned because the natural gas sensor is connected neither to an automated shut-off system for the natural gas supply nor to an alarm, thus increasing the likelihood of an incident and its potential severity.

b)     Although maintenance is supposed to be done quarterly on the natural gas lines and equipment, no evidence is found that maintenance has ever been performed since they were first installed four years ago. Such maintenance typically involves checking for and fixing gas leaks. Also, no training has been provided to workers on either understanding the potential for explosion, or the steps to take to avoid an explosion. In fact, most workers did not even realize the potential for an explosion existed. Furthermore, no written procedures relating explosions exist within the plant.

c)      The plant contains toxic materials that can harm people and animals. The way this material is stored in the plant, it could, in the event of a plant explosion, be released and impact an area within one kilometer of the plant. Such an incident could lead to illnesses or deaths among members of the public and could harm animals in the environment.

 

Questions:

1)     What are the unsafe conditions and acts in the plant?

2)     What are some steps can be taken to rectify the noted safety concerns?

Answer 1

1) What are the unsafe conditions and acts in the plant?

Answer : As it is a Appliances Manufacturing Plant in which several activities are perfomed and the plant utilizes electricity and natural gas extensively.

One of the most hazardous condition is there is only one natural gas sensor which is a simple sensor which has no alarm or intelligent device, for that sensor a manual activity have to be done to shut the system or to on/off the gas supply and moreover it is wrongly placed means where there is the potential for an explosion could exist there is no safety device which can sense any hazardous condition.

Lack of maintenance or inadequate maintenance can lead to dangerous situations, accidents and health problems. Maintenance is a high-risk activity with some of the hazards resulting from the nature of the work. Expert has no evidence found that maintenance has ever been performed since they were first installed four years ago. So this is another hazardous condition.

No training is given to operators and they are not even to able to overcome from any emergency or accidental or hazardous condition.There is no visual warning board through out the plant which can guide what are Do's and Don'ts.

Every plant has some undesired or non-echo products or toxic materials. these substances are that may cause serious harm to an individual if it enters the body. But in this plant ther is no proper system for handling these materials.

2) What are some steps can be taken to rectify the noted safety concerns?

Answer : There are many places where automated and intelligent sensors are required to act. Use as much as possible automated and intelligent sensors that can sense and shut off the running processes itself immidietly in case of emergency.

Maintenance activities focus on operating the power plant at maximum efficiency, automating critical operations and providing essential data to power plant operators. Regular maintenance is essential to keep equipment, machines and the work environment safe and reliable. So it is highly reccommend that a scheduled and preventive maintenance is required to be done to ensure the overall safety of plant eqquipement and workers.

Relative wages of highly skilled workers have increased and the relative wages of less-skilled workers have decreased. So it is required to give necessary training to the workers and labors to overcome from these conditions. Add visual warning board through out the plant to make the state and condition of manufacturing processes easily accessible and very clear – to everyone. It helps the industry guide, monitor and ensure productivity. These boards can be use in manufacturing, inventory management, storage, receiving, picking and shipping.

For the storage of toxic materials, ensure that the storage area is clearly identified with warning signs, is clear of obstructions, and is accessible only to trained and authorized personnel.

Before storing toxic materials, inspect all incoming containers to ensure that the containers are undamaged and are properly labelled. Do not accept delivery of defective containers. Also, be sure to store toxic materials in the type of containers recommended by the manufacturer or supplier.

Some other important points for storage of toxic materials include:

Keep the amount of toxic material in storage as small as possible.

1. Inspect storage areas and containers regularly for any deficiencies, including leaking or damaged containers, expired shelf-life or poor housekeeping. Correct all deficiencies as soon as possible.

2. Ensure that containers are tightly closed when not in use and when empty. Keep empty containers in a separate storage area. Empty containers may contain hazardous toxic residue -- keep closed.

3. Store containers at a convenient height for handling, below eye level if possible. High shelving increases the risk of dropping containers and the severity of damage, injury and/or exposure if a fall occurs.

4.Store material within the temperature range recommended by the chemical manufacturer/supplier.

5.To contain spills or leaks, the toxic material containers should be stored in trays made of compatible materials. For larger containers such as drums or barrels, provide dikes around the storage area and sills or ramps at door openings. Storage tanks are above ground and surrounded with a dike capable of holding entire contents.