Inspection of a Plant Stor

Bad Observations	Control Measures		Timescale
Hazards and Consequences	Immediate and Longer Term Actions
Fire Hazards- We observed plenty of lighted cigarette ends that posed danger to the store. If left on its own, this could make the whole store to burn down. Risk of fire	A ‘no smoking’ policy should be adopted in the entire store and staff should be given designated smoking areas which should be closely supervised. There should be a separate gas storage area as well.		ASAP 1 Month
Faulty Electrical Fan We saw some of the electrical appliances had been subjected to misuse hence causing electric faults on apparatus. Risk of electric shock or fault	Take action immediately to avoid accidents.		Immediate
Fire Fighting Equipment During our inspection, we observed inadequate fire-fighting equipment; we asked a worker regarding fire-safety measures; he told us that they use water pots to pour water on the fire, if any incident happen. Risk of fire; it will be difficult to tackle the situation in a case of fire	Purchase fire-fighting equipment immediately Arrange firefighting training sessions for the staff		Immediate 2 Months
House Keeping Rooms were a high fire risk area since many flammable goods were stored with minimal supervision. Difficult access to equipment and plant due to poor house-keeping arrangement Exposure to noise was also observed Risk of fire and risk of fatigue involved; deliveries could be delayed	Staff is required to setup its housekeeping facilities and create appropriate storage e.g. racking Dangers should also be discussed at sessions of training. Maintaining a proper house-keeping rules and workshop training Assessment of noise risk is necessary and after assessment, prevention measures should be used		One week 1 Month 1 Month 1-3 Months
Hazardous Substances No proper labelling was done in the chemical substances storage. We also observed that some of the staff didn’t know the safety measures of the harmful chemicals and other substances. They were asking seniors for the help. Risk of wrong chemical utilization or an outdated item could be used	It is important to identify and control risky substances. Rearrange all the chemical substances storage and staff should ensure proper labeling clearly. It is important to improve safety knowledge of staff with regard to the danger of the harmful substances as well as utilizing of PPE. A one day workshop should be arranged for all staff to improve their knowledge regarding chemicals and other substances. A training course should be arranged for staff to empower them with practical training on chemicals, pesticide and PPE. Appropriate PPE training per individual can reach to 40 USD or training cost can be reduced by conducting training through own staff; thus, cost could reduce to working time while training.		1 Week One-day 1 Month 1 Month
Working Practices We noted that some workers were using old techniques of gardening in the workshop. Up-to-date training courses are really important in management; so, the staff is required to attend updated courses to know the operational mediums, tools and implementing techniques of the day. Risk of delay in deliveries and waste of time involved	A one-day training course should be attained as soon as possible by all the staff. Estimated cost can reach to USD 150 per head. This expense can be reduced if the training, safety measure training is conducted by the company staff and safety advisors. Thus, the cost would be reduced to the staffs’ equivalent time.		1 Day 1-3 Months
Welfare Provisions Employees were smoking and drinking water at the workplace Risk of ingesting hazardous, fire and injury involved	A room should be provided for rest, preparing drinks or taking meals. This may attach with kitchen and empowered with various appliances. It should be well-ventilated to prevent fire smokes, etc.		1 Month
Plant Maintenance and use of Fixed plant like bench saw, lathe, band saw Lack of proper training and operating competence of workers observed Risk of electrical or other faults Poorly maintained plant Risk of downfall in sales Workers handling everything by hand Risk of injuries from manual handling of plant	Tagging and testing electrical equipment should be done Wearing personal protective clothing Scheduling workshop inspection		1 Week 1 Week On a Monthly base
Use of chemicals like Degreasers, lubricants and coolers Incompatible chemicals stored together Risk of lead to explosions, fires and release of toxic fumes Chemicals were used in unsuitable containers Risk of any damage Physical contact with chemicals was also observed Risk of injury	Risk assessment in determining where chemicals are delivered Securing of gas cylinders Use of appropriate protective clothing Storage of chemicals in smaller containers Risk assessment of where chemicals are delivered		1 Month 1 week 1 Week 1 Week
Welding Manual handling of welding equipment Risk of injury Fumes, hot metal burns were also handled manually Risk of injury	Have a dedicated welding bay Checking and maintaining of welding equipment and having trained operators Having a trained operator Unearthing welding equipment should be installed		1 Week 1 Month 1 Month 1 Month
Use of mobile plant like overhead crane and other devices used for lifting. Risk of injury Inappropriate safety measures like emergency stops were also observed Risk of muscle pull or other injuries	Preoperational checks should be done This practice should be stopped immediately		Monthly Immediately
Better Safety Measures Observations
It is observed that the workplace was clean and everything was on its spot. All tools and equipment were properly placed at their exact places.		More attention is required Inspections should be done on a monthly basis	ASAP On a monthly basis
It is also observed that the atmosphere of the workshop was up to the mark. Air quality was good and dust was controlled properly. Staff used vacuum cleaner for indoor places, and sweeping and water wash-down for outdoor places, whereas for the inaccessible places, staff used ‘blowdowns’/compressor.		Safety measures should be observed to prevent dust from the shop and workshop. Dust can damage equipment or can reduce the life of the tools, so, cleaning should be done on a daily basis	Immediately On a daily basis
We noted that power is usually disconnected before any adjustments can be made to the power tools. We also realized that any energized equipment is not serviced. This is a safety workshop measure.		Staff should put more attention on this safety measure, as this, not only save the employees from any danger, but also will save the energy Sensors should be used to power off the ‘ not in use’ equipment and tools	Immediately 3 Months
Another positive aspect that we noted is that while working on the machines, the workers did not wear loose fitting clothes, gloves, dangling jewelry, neck ties or baggy sleeves that could be entangled in the tools or be an obstacle during the work.		A supervisor should check the clothes of the staff on a daily basis Proper uniforms should be provided to the staff	Immediately 3 Months
As we were carrying out the inspection, one of the workers came to report an accident that had occurred to the head of the division, who immediately directed the appropriate first aid measure. This was a positive action as we verified that accidents are promptly reported and acted upon.		All safety measures should be observed in the shop and workshop to avoid any accident. A standby ambulance should be available every time to transport any patient to the hospital	ASAP 6 Months
We noted that as workers carried out their duties, the tool guards and safety measures were kept in place and not removed.		A supervisor should check this on a daily basis A safety audit should be done to verify and recommend safety guards and tools	Immediately 3 Months
We noted that workers took suitable fire prevention precautions when work generated sparks or heat, flames or flammable liquids such as work on a plant pot or container.		Firefighting tools should be installed at all important places Water sprinkler system should be installed	ASAP 3 Months
Another observation was, the work-area mats and clothes were clean and without sticky tapes. As well as soiled and dirty clothes and other useless items disposed of appropriately.		A supervisor should check this security measure on a daily basis	On a daily basis

Introduction

We carried out an inspection at the Plant’s Store and Workshop on 10^th March, 2016 at about 11.00 am. Incorporated in this report are the issues that came up while doing the inspection. This company is ISO 9000, 9001 and 14001 certified with regard to the management of the environment and is following a perfect approach. This report addresses hazards related to the Plant’s Store and Workshop, and also includes recommendations that may minimize the likelihood of these hazards reoccurring. The inspection concerns internal matters and factors that are linked to this project. The major activities in this inspection include controlling, monitoring and evaluating hazardous activities being conducted during this project’s execution. The Plant’s Store and Workshop is used for repairing the mechanical failures of all company machines and plants in the workshop, where all the stock and tools are kept. There is one watchman at the store and six other fitters at the workshop which consists of:

i)                    A workshop area with hand and mechanical tools such as hydraulic jacks, Spanners, welding equipment, garage pits and other tools together with many other hazardous items such as solvents and oils.

ii)                  A storage area for workshop and company materials, including safety tools and equipment such as forks, hand shovels and PPEs.

iii)                A store keeper area, with a computer station and small desk.

During the period of inspection, a few activities were going on; hence, the recommendations and observations that are included in this report are solely on the observed conditions and workplace.

The purpose of carrying out this inspection was due to an increased number of incidents and accidents reported from the same area. The standard of health and safety was generally found to be lacking. During the inspection, there were a number of deficiencies observed that showed general slackness in the area of supervision and work practices.

Executive Summary

The Plant’s Store and Workshop is a well-executed and effective system of management. Health and safety are well-managed. Nonetheless, there are points that came to our attention during the inspection. According to the inspection, it was established that health and safety were lacking in five major areas. The store has a few main indicators that require immediate attention and there are also long-term objectives that need to be met in order to ensure that the project’s quality is achievable. Occasional injuries and death of workers may also be minimized if suitable measures are taken to rectify the audit issues that surfaced during the inspection. This report is in compliance with the 1992 Regulations, Workplace breaches (Health, Safety and Welfare), the 2002 Control of Hazardous Substances to the Health Regulations and the 1990 Environmental Protection Act, as well as the 2005 Fire Safety Regulatory Reform. In the case that the breaches are not resolved, legislative issues may result, including criminal prosecution as well as the subjection of the organization to substantial fines

Major Findings of the Inspection

Fire Safety

Stores are generally considered to be of moderate fire risk, as fires usually occur due to carelessness and unknown arson attacks.

We noted careless discarding of smoking materials, particularly if allowed to get in contact with flammable materials. There were plenty of litigarette ends that posed danger to the store, as if these are left unattended, may result in the development of a fire sufficient to burn down the premises. As such, a ‘no smoking’ policy should be adopted in the entire store, and staff given designated smoking areas, which should be closely supervised.

Faulty Electrical Fan

We noted that electrical appliances had been subjected to misuse, resulting in electrical faults on apparatus due to a lack of regular servicing. Therefore, all electrical equipment should be annually tested, and all staff should be kept informed of the possible dangers associated with various types of equipment.

Part of the plastic cover is broken and there are parts that are accessible to touch. In case such a situation arose, then accidental electrocution can arise with possible fatal consequences. Action should be taken immediately in order to avoid the possibility of accidents and subsequent loss of time and possible compensation awards and increased insurance premiums.

Fire Fighting Equipment

We noted that there was no adequate fire-fighting equipment. When using items such as gas torches, blow lamps, metal angle-cutters and other apparatus that can cause a fire, it is important to maintain a high degree of supervision.

House Keeping

We noted that the store rooms were a high fire risk area, as many flammable goods were stored there with minimal supervision. We also noted that there was difficulty in accessing plant and equipment as a result of the poor arrangement. There was a lot of noise exposure. As such, there should be improved housekeeping, and all stores should be kept as tidy as possible so as to minimize risk. This is also applicable to the premises at large. Dangers should also be discussed during training sessions.

Hazardous Substances

We noted the lack of PPE materials, which may lead to eye trauma and harm, especially when the filling takes place in the absence of proper eye protection equipment. Moreover, the chemicals are stored in unlabeled bottles, which, if incorrectly used, may result in serious injury.

Welfare Provision

We noted that there was no adequate place for drink preparation, as well as no smoking and drinking areas. All these should be improved by the refurbishment

Escape Means

Emergency exits should be installed, and it should be guaranteed that they stay accessible and unhampered. Work zones that are above ground or subterranean, should provide exits to ground-level in all possible locations. It is vital that escape routes offer access to a protected area where individuals can gather and be represented.

Conclusion

From the inspection carried out, there is a need for general improvement in regard to health and safety measures. I would recommend that there be a greater awareness of safety measures, which would help to eliminate most of the issues that were identified today. I would therefore suggest that the company invest in employees by providing safety awareness training for each and every employee. This would help to improve inspection and maintenance routines, and eliminate many of the lazy and careless practices that may occur. I would suggest that the benefits of such an investment would improve work practices, enhance efficiency, minimize accidents and improve morale at the workplace.

All the above observations require immediate attention and action in order to minimize the risk of accidents and ill health in the store and workshop, which will consequently result to better productivity and motivation. These improvements will help to reduce direct and indirect costs associated with any accidents that may occur.

All staff should attend to a one-day training course regarding workshop safety, and safety awareness issues that were identified during the inspection should be made known to every staff member. Having a greater awareness with regards to safety issues would have a great impact towards eliminating most of the issues that were identified today.

Occupational health and safety is an issue that needs proper management. Failure to take heed of this report would result in the company facing law enforcement action due to a breach of the legislature. Moreover, if this report is ignored, it will affect the company’s image due to the losses and accidents that may take place and regrettably, it will affect the development of the business, which may result in greater difficulty in acquiring more projects and contracts.

Any court case is capable of drawing adverse publicity on the company and this may erase all the good work that the company has done in building up the client base and which may in turn affect orders in future. This could even threaten the company's existence or even its future profitability. Senior managers are required to be mindful in such countries as UAE and UK since there is the potential of being charged with manslaughter in case you engage in an accident that relates to work which may result in the death of a worker or any other person affected by working activities.

Management is required to investigate accidents and when there is time loss from work, they have to reorganize work- loads and at times training and retraining has to be done. All these have got own impact on the organization.

Accidents resulting from personal injury usually cause pain and suffering to the victim. More serious accidents may affect a wider circle of friends, workmates and family. Witnesses of serious accidents also cause trauma. People have got every right to be protected from hazards at the place of work and managers have a right of ensuring that this protection takes place.