Journal Mrcie 2015 1fe11

MEASURING THE EFFECTIVENESS OF HAZARDOUS CARGO SAFETY HANDLING IN WAREHOUSE BASED ON THE CASE STUDY AT BASF CHEMICALS AT JOHOR PORT.

AMPIGAAH SIVAN, MUHAMMAD NAZREEN NASHARUDIN AND NURUL SYAKIRIN MD AHIR

Abstract

Safety and health are important elements in a chemical warehouse. There are several causes and approaches to reduce the incident from occurring but not many have found the appropriate method to minimize accidents in the warehouse. The number of accidents occurred in chemical warehouses increases annually. Every warehouse or organization has to comply with the safety policy. But how effective is the policy towards one’s company? The safety policy affects the internal safety of the warehouse thus preventing accidents from occurring. The more effective the safety policy, the lesser accidents would occur in the warehouse. There are a number of factors that affect the policy for example, material handling issues and the layout of the warehouse. If these factors are unable to be imple.0mented, then the policy would not be effective towards the warehouse management. This research proves the effectiveness of safety policy in a warehouse could reduce accidents from occurring. By using coding method where thematic analyse is applied, it analyses the factors that affects the policy and determines the effectiveness of the safety policy that is implemented by the warehouse. Keywords:

Chemical Warehouse; Safety Handling; Hazardous Cargo; Measuring Effectiveness

INTRODUCTION Most accidents of leakages and release of toxic that occur in warehouses are during the activities such as loading, unloading, storing and packaging. A common human error could lead to a massive explosion. Another critical issue is the increase of low experience workers in handling activities which contribute to the increasing accident rate. (Steenbergen, Gelder, Miraglia, & Vrouwenvelder, 2014)

There are many types of chemicals that are being manufactured in this world as listed out in the safety sheet book known as the International Marine Dangerous Goods Code (IMDG). There are about nine classes of dangerous good where been list in Dangerous Good Health and Handling Guidelines (2013) as below table:

Class

Type

1

Explosive

2

Gases, Compressed, liquefied or dissolved under pressure

3

Flammable liquids

4

Flammable solids

5

Oxidizers and organic peroxides

6

Toxic substances

7

Radioactive substances

8

Corrosive substance

9

Miscellaneous dangerous substances

Figure 1.1: Table of dangerous good. (Source: Dangerous Good Health and Handling Guidelines (2013) Health and safety aspects need to be integrated in the planning process of the maintenance operations. Issues to consider include potential hazards and risks, health and safety communication, competence of health and safety training, and the impact of maintenance in of health and safety on others in workplace. Emergency procedures, safe access and egress also need to be planned. An initial risk assessment could be completed thus control measures and site rules could also be defined at this stage. Consideration should be given to the need for work permits and similar procedures. (EU-OSHA, 2007)

Restrictions of Chemicals) was enforced on June 1, 2007. It is based on the principle that industry needs to ensure that substances manufactured, commercialized or exploited does not affect human health and environment. This regulation would be achieved by being implemented to the management of chemicals to the industry. (Omar & Mathieu, 2011).

According to Babin & Kendra (2013), work complexity decreases under trend influence of work safety improvement and quality improvement resulting into increase of working unit efficiency which reduces cost.

Therefore, this research paper would discuss new management and precaution ideas that need to be generated to avoid or reduce such occupational risk in BASF Chemicals.

Regulations nowadays are very concerned about environmental health which could be damaged by the mishandling of chemical substances. The Europe regulatory framework for chemical substances called REACH (Registration, Evaluation, Authorization and

In addition, the different categories of hazard minimize measure are divided into four which are human factor, environment, organizational and equipment (Konster, Davelaar & Marten, 2010)

MATERIALS AND METHODS METHODS: INTERVIEW RESPONSES AND JOURNAL/BOOKS.

Interviews were recorded and rewritten as transcripts. The interviews were conducted with the person in-charge of the chemical

warehouse. Interviews were conducted one on one as more information could be retrieved when done in such way. This method contributes to the validity of data whereby data obtained are more genuine. The variables consist of randomly selected employees which handled the goods in the chemical warehouse area. Employees are selected from different management levels. 1) Labourers 2) Safety Officers 3) Supervisors 4) Safety Manager The respondents were selected from three different fields that were related to this study namely the supervisor of BASF Chemical, Fire Department officer and an officer from the Environmental Department. Result of the interviews were analyzed using thematic analyze approach which had been divided into three categories. a) Training and Practical b) Handling Equipment c) Layout and environment

RESULTS AND DISCUSSION A) TRAINING AND PRACTICAL I.

UNCERTIFIED WORKERS HANDLING

Material handling is loading, moving and unloading of materials. To do it safely and economically, different types of tackles, gadgets and equipment are used, when the materials handling is referred to as mechanical handling of materials (Bolz, H. A and Hageman, G. E (ed.), ‘‘Materials Handling Handbook’’,) Ronald Press.

The warehouse supervisor was questioned if the workers were certified to handle the chemicals as well as the material handling equipment inside the warehouse. According to the supervisor, usually the middle layer employees such as the supervisors and executive managers whom control the handling of chemicals in the warehouse. In Malaysia however, there is no emphasize on this matter resulting general workers to handle chemicals in the warehouse thus enabling organization to reduce the cost on employee training. Although, based on a respondent from the Fire Department, it is recommended that only trained professionals handle the equipment to avoid accidents or spillages from occurring. Unless there is a shortage of experienced workers then potential workers could be given in-house training and certified to operate the equipment. II.

HANDLING SPILLAGES AND LEAKAGE PROBLEM

Chemical spills often occur in warehouses due

to the negligence of employees. Spillages should be cleaned immediately in correct manner as not to pollute environment or injure employees. According to BASF Chemicals Supervisor, each employee is required to attend a 3 week training period on how to manage leaks and chemical spills. The eight types of training involve fire drills, first aid training, and spillage training. In the event of a spillage, the workers are required to wear a special attire that includes gloves, boots and yellow absorber which could be found in the spillage kit. Employees are to ensure that the spilled chemicals do not flow into drains or exposed to life as these chemicals are hazardous. If in with the drainage system, it might

pollute rivers and the sea thus disrupting sea life and its ecosystem. III.

EMPLOYEE ATTIRE AT THE WAREHOUSE

Workers are required to wear attires that are neat, clean and well maintained. Torn attires, dirty or frayed should not be used for work. In addition, the clothes should be appropriate for the working environment such as heavy duty boots, coveralls and helmets. As mentioned by the warehouse supervisor, employees at BASF Chemicals does not wear the before mentioned attire although it has been mentioned in the rules and regulations of the warehouse. The Fire Department and Environmental Department personnel’s also agreed that it is vital for the employees to wear the correct attire proposed so as to avoid injuries in case of explosions, leakages or material handling equipment accidents.

B) IV.

HANDLING EQUIPMENT

FREIGHT FORWARDER RESPONSIBILITY IN SHIPPING

BASF Chemicals used forwarding agents to transship chemicals such as raw materials to be sent to another factory. Freight forwarders would manage the movement of goods out of the warehouse so far as the designated sites. Based on response by the warehouse supervisor on transshipment material handling it is said that every chemical is to only be transshipped according to the guidelines mentioned in the IMDG code before the delivery process. This is to avoid from any accidents from occurring as well as safety measures to be taken into in the event of spillage or explosion.

Warehouse personnel’s are required to affix the label to the container before transporting the goods out. Old labels must be removed and replaced. A new label is required each time a dangerous good enters or exits the perimeter of the warehouse. V.

USE OF FORKLIFT

Material handling equipment is used to increase output, control costs, and maximize productivity. Although if not used in the advised manner or used by an inexperienced warehouse personnel could lead to major accidents in the warehouse which could damage both goods and cause injuries to workers around. Warehouse employees are trained to control the forklifts as to lift and carry chemical goods in the warehouse. To operate a forklift in the warehouse, operators must comply with the chemical forklift speed limit that has been set. This is to prevent accidents from occurring in the warehouse. In addition, the chemicals should be properly controlled to prevent chemicals in liquid form, falling off forklifts. If liquid chemical leaked, it could harm workers inside the warehouse as well as surrounding warehouse environment.

C) LAYOUT VI.

LAYOUT APPROVAL FROM FIRE AND ENVIRONMENTAL DEPARTMENT

When developing layout of warehouses it is most crucial to get approval from the Fire and Environmental Department as they will vet the safest way escape route as well as environmentally safe layout for both company

and its workers. Without the approval from both departments, the warehouse would not be allowed to function. According to the warehouse supervisor’s response, approval to their warehouse was given three months before implementation and as mentioned by the Fire Department personnel, the warehouse supervisor will submit the layout 6 months prior to its implementation for approval. And once it has been approved the warehouse will be checked from time to time by the Fire Department as well as Environmental Department. VII.

CHEMICAL SORTATION

One of the most dangerous warehouses is the chemical warehouse. The mixture of the smallest amount of different chemicals could lead to massive explosions and casualties’ hence crucial precautions were needed to separate all chemicals according to their types and surrounding temperature requirements to prevent reactions. The Fire Department responses by saying that it is most crucial for the warehouse authorities to segregate the chemicals in the warehouse according to the types and level of dangerousness to avoid mishaps from occurring. Moreover, the Environmental Department also mentioned that chemicals need to be stored according to the labels in places with the right temperature as the wrong temperature of storage drum material could cause chemicals to react or even corrode the drum causing leakage that could seep into the drainage system and spread to rivers thus disrupting marine life. DISCUSSION

Many procedures need to be fulfilled in order to maintain safety for hazardous cargo as if unhandled properly it could cause harm to humans and environment. From the point of security is very important in dealing with dangerous cargo. It must be approved by the Fire Department and environment department. The Fire Department will inspect the layout of the cargo in the warehouse. The warehouse layout that is implemented is done by BASF which requires the approval of the fire department in order to be assessed the level of security in the warehouse. In the environmental perspective, BASF ensured that no chemical residues were to be released into drains or rivers. The Environmental Department also examined the management of toxic waste. These chemicals are very dangerous if not handled properly and would cause an adverse effect on humans and other livings. Each of these chemicals should be separated to avoid reactions that might endanger the safety of workers in the warehouse. CONCLUSION An effective safe environment in a warehouse could be made through emphasizing the rules given together with cooperation both management and employees. The rules and regulations in chemical warehouses are vital. Even the most basic safety precautions of wearing fully covered attire could mean a life or death situation to its employees. The warehouse authorities should make it compulsory for all warehouse operators to wear coveralls to prevent any injuries to operators while on the job also during emergencies.

If not a fine could be issued upon the worker who does not follow the proper attire regulation. As a chemical warehouse handles many hazardous types of chemicals, it is vital for employees to use coveralls to prevent chemical skin which could lead to corrosion of the epidermal layer or even serious injuries. Employees are also recommended to get check-ups once every 6 months as they are exposed to chemicals all year round. Moreover, adhering the right chemical disposal and leakage procedures are important as the smallest amount of chemical leakage into the drainage system could destroy vegetation and marine life. The warehouse management could send its uncertified employees for training and examination before allowing them to handle the chemicals and equipment in the warehouse. To be even sure, it is advised by the environmental and Fire Department that the warehouse management should only hire experienced, certified personal to lower the risks of material handling faults. ACKNOWLEDGEMENTS First and foremost, all praises to God for giving us the chance to complete this research with much success. The authors would like to thank BASF CHEMICALS, Johor Port for allowing us to conduct our research in the warehouse. The authors would also like to thank Madam Rozelin Abdullah, Miss Nur’ Aqilah Bt Mohd Norain and Miss Nadzirah Abd Hafith for ing this research by providing continuous , valuable guidance, patience, fruitful advices thus guiding us both directly and indirectly throughout the completion of this research. Last but not least our deepest heartfelt

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