Implementation of Integrated Management System:

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009 Implementation of Integrated Management System: Environm...
0 downloads 1 Views 318KB Size
3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

Implementation of Integrated Management System: Environmental and Safety Performance and Global Sustainability

Au Yong Hui Nee

09000 Kulim, Kedah, Malaysia. [email protected]

Environment, Safety and Health Department Hoya Electronics Malaysia Abstract — ISO 14001 environmental management system assists organizations in creation of structured mechanisms for continuous improvement in environmental performance, while the OHSAS 18001 occupational health and safety management system helps organizations in industrial operations that involve various occupational risks. ISO14001 shares many common traits with OHSAS 18001 and this has paved the road for the idea of an integrated management system. The aim of this study was to determine the extent of involvement in best environment and safety practices in the recycling industry towards development of environment and safety culture. The paper evaluates how the management systems aids companies in operating continuous environment protection programs to minimize significant environmental impacts, accidents and diseases by exploring some critical elements for success including task-based risk assessment and emergency preparedness and response. This analyze is carried out supported by secondary data obtained from environmental and safety reporting. This paper discusses the experiences of the management system in the recycling industry. Effective integration between environmental and safety awareness will create companies and employees who are responsible towards environment conservation and implementation of safe work practices. Environmental Management System, Occupational Safety and Health Management System, Integrated Management System, global sustainability

I.

lifestyles and personal health skills, health services and impact on the external environment. Environmental legislation relevant to pollution control via emissions to air, discharge to water and disposal to land rely mainly on Environmental Quality Act (EQA) 1974. According to the Labor Force Survey, by second half of 2008, they were 11.1224 million employed persons. The number of employed persons data show that the manufacturing sector employs 1.9576 million persons (17.6%) and construction sector employs 1.0142 million persons (9.1%) of the work force [1]. The number of Industrial Accidents Reported to Social Security Organization (SOCSO) has been reduced from 109,447 cases in 1994 to 81,003 cases in 2003, and from 68,008 cases in 2006 to 38,655 cases in 2007. The industrial accident reported per 1,000 employees is summarized in Fig. 1. Accident during transportation to work has also reduced from 18,309 cases in 1999 compared 17,682 cases in 2007. The Rate of Accident has been improved from 13/1000 in 1996 to 4.2/1000 in 2008 [2]. The OSH level need to be further improved to be on par with advanced nation in line with Vision 2020.

INTRODUCTION

There are various types of accidents such as fire, explosion, chemical spillage and severe and fatal accidents industrial accidents happened at workplace. Lessons from accidents have influenced environment and occupational safety and health (OSH) legislation as well as the acceptance of environment and OSH management systems as best practices among the companies. Environmental and OSH (ESH) hold an interesting, integrated position across all business sectors, driven by a dynamic legislative environment and new information on hazards and impacts, and evolving management systems. The main purpose of the OSH rules and legislation is to prevent accidents, ill health and injury at workplace. Employers are required to ensure the OSH and welfare of their workforce under Occupational Safety and Health Act (OSHA) 1994. Requirements of a healthy workplace has been incorporated with elements of consideration on workplace policies, organizational environment, physical environment,

Figure 1. Industrial accident reported per 1,000 employees Source: Labor and Human Resource Statistics (Ministry of Human Resources)

The Number of fatality was 907 in 2003 and 1292 in 2006. The Number of occupational fatality in 2008 was 230. Fatality by the top three sectors was 76 in manufacturing, 72 in construction, and 42 in agriculture, forestry, logging and fishery. The fatality rate has also reduced from 155/Million in 1996 to 69/Million in 2008. The fatality rate in the construction industry was of more than three times of al workplaces (3.3% in construction sector compared to all

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

workplaces of 1.1%) [2]. There is better OSH management and practices in the petrochemical industry as compared to civil construction industry are due to industry standards and drives by the customers. One of the importance factors in implementing internal control to ensure that companies comply with the environment and OSH (ESH) legislation is plant management's motivation, where high consequences of severe accidents have played vital parts as they are associated downtime and compensation costs. As of Jul 2009, they were 2,496 competent safety and health officer registered with Department of Occupational Safety and Health (DOSH) [3]. DOSH issued 5,559 notices in 2008 to companies for failure to provide a safely and healthy workplace to comply with OSHA 1994 [4]. DOSH has also increased punitive action against employers to 320 cases in 2008. In terms of compliance to main requirements of OSHA 1994, it was 84% on Section 30 (Safety and Health Committee), 76% on Section 16 (Safety and Health Policy) and 72% on Section 29 (Safety and Health Officer) [5]. DOSH enforcement of notices and prosecution cases from year 2003 to 2007 is summarized as shown in Fig. 2.

Figure 2. Number of DOSH notices and prosecutions Source: Labor and Human Resource Statistics (Ministry of Human Resources)

On Department of Environment (DOE) enforcement, in 2004, a total of 208 environmental offences were prosecuted in court, compared the peak in one decade in year 1999 for 307 cases. The pattern of the court cases seems to be closely related to the economic growth of the country. Of these cases, 63 (30 %) cases were involved in offences related to pollution of inland waters under Section 25(1) (pollution of inland waters) of the EQA 1974. For open burning cases, 16 (7 %) cases were prosecuted. A total of 5,128 compounds were issued in 2004 against premises and companies for various offences under EQA 1974. Of this total, 3,692 (72 %) were offences under the Environmental Quality (Control of Emissions from Diesel Engine) Regulations 1996; 473 (9 %) were offences under Section 29A (prohibition on open burning) of EQA 1974; 445 (9 %) were offences under Environmental Quality (Clean Air) Regulations 1978; 408 (8 %) were offences under Environmental Quality (Schedules Wastes) Regulations 1989; and 110 (2 %) were offences under Environmental Quality (Control of Emission from Petrol Engine) Regulations 1996. The number of air pollution complaints far exceeded other types of complaints totaling

2643 (73%); 363 (10%) for water pollution; 177 (5%) for noise pollution; 122 (4%) on illegal dumping of scheduled or toxic wastes in 2004 [6]. Recent trend in focusing occupational safety and health research towards risk management is accelerated by the growing attention to occupational safety and health management systems. ISO 14001 environmental management system helps organizations in creation of structured mechanisms for continuous improvement in environmental performance by continuously reducing resources consumption, while OHSAS 18001 help organizations in industrial maintenance operations that involve various occupational risks. ISO 14001 determines environmental aspects and shortlists significant impacts, manages control over operations and monitors of performance. ISO14001 shares many common elements with OHSAS 18001, and the latest versions of ISO 14001 in 2004 and OHSAS 18001 in 2007 share increased similarities. ISO 14001 and OHSAS 18001 focus on processes, and there are certain common elements in management systems that can be identified and be managed in an integrated way. This has paved the road and made an organization easier for companies to comply with several standards, while organizations are required to demonstrate management systems that satisfy various stakeholder demands. The Government had carried out various efforts to assist in emphasizing quality, environment and OSH among Malaysian companies. The expenses associated with certification of international standards by accredited certification bodies are exempted from the corporate tax. Small and Medium Industry Development Corporation (SMIDEC), a government agency responsible for small and medium enterprises (SMEs) development supports implementation of ISO 14001 in SMEs. Besides the OHSAS 14001 international standard, Standards and Industrial Research Institute of Malaysia (SIRIM) has also developed a Malaysian Standard OSH MS (MS 1722: 2005), mainly referred to International Labor Organization (ILO)'s Occupational Safety and Health Management System (OSHMS). The later standard is encouraged to be adopted by construction companies driven by Construction Industry Development Board (CIDB) under the Do-It-Yourself program. These initiatives are underway to increase productivity by inculcating OSH culture in the standards in OSH i.e. the OHSAS 18001 and MS 1722, especially for contractors grade 7 [7]. The Work Ministry intended to make ISO a mandatory requirement for class “A” contractor as a condition to obtain high value project in the Tenth Malaysia Plan [8]. Corporate Social Responsibility refers to a set of policies and strategies that are said to occur when companies integrate social and environmental concerns in their business operations and in their interaction with stakeholders [9], among others are those related to occupational safety and health and environmental sustainability. Proposed regulation to make OSHMS a compulsory to high-risk industry is a step forward to minimize workplace accident.

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

For the certified organizations by Department of Standards Malaysia [10] accredited certification bodies (CBs), there are a total of 4591 for ISO 9001 QMS, 734 for ISO 14001 EMS and 344 for OHSAS MS (OHSAS 18001: 2007 and MS 1722: 2005), with the overwhelming concentration in the QMS. However, the importance of EMS and OHSAS are given relatively higher emphasis at certain sectors. From the number of QMS: EMS: OHSAS certification, OSH seems to be emphasized especially by sectors of food products, beverage and tobacco is 227:93:91, concrete, cement, lime, plaster, etc. is 120:11:13, construction is 671:25:33, transport, storage and communication is 159:9:17 and engineering services is 259:13:19, while environment is emphasized by the sectors of manufacture of coke and refined petroleum products is 19:8:3, rubber and plastic products is 341:82:11, basic metals and fabricated metal products is 394:71:23, electrical and optical products is 325:150:38 and recycling is 12:22:5 as summarized in Table I. TABLE I. INTERNATIONAL STANDARDS CERTIFICATION BY SELECTED INDUSTRY ISO ISO OHSAS 9001 14001 18001 Coke & Refined Petroleum Products

19

8

3

Rubber & Plastic Products

341

82

11

Metals Products

394

71

23

Electrical & Optical Products

325

150

38

Recycling 12 22 5 Source: Accredited Certification (Department of Standards Malaysia)

II.

LITERATURE REVIEW

Voluntary disclosure of environmental, OSH or social responsibility is uncommon, unless is required by the legislation. Reference [11] concludes that the decision to disclose voluntarily the environmental issue in the annual reports in Malaysia is negatively correlated with companies’ financial leverage. For research in relation to OSH, Reference [12] compares the main published projects to identify research priorities in the OSH field, methods, approaches and results. On the other hand, there are substantial volume of literature on integration of quality / environmental / OSH management systems around the world. Reference [13] concluded that they are two approaches to integration of quality, environmental and occupational safety and health management systems in UK i.e. merging of the documentation (the aligned approach), and implementation of an integrated management system (IMS) (the total quality approach). Reference [14] reviews the driving forces behind integrating management systems into a unified system and discusses methods to leverage existing ISO 9000 quality structure in the US. Reference [15] discusses a

practical applications approach to design, develop and implement an integrated management system encompassing quality, process safety management, risk management programs, environmental management, and occupational safety and health in the US. Reference [16] analyzes the development, the organizational challenges, the experiences and the IMS standards in Danish and Spanish context. Reference [17] developed an integrated Safety, Health, Environmental and Quality Management System’s guidelines for the construction industry in Malaysia. On the outcome of management systems, reference [18] outlines the ESH approach with successful implementation of prevention through design principles of a Canada company, and identifies a key enabler to improving ESH performance as the sharing of knowledge. Reference [19] discusses theoretical review on OSH management in construction industry. Reference [20] concluded that the most significant aspects piling and foundation works were the activities from the drilling process, transportation, machinery activities and generator set operation, and mitigations measures identified which involved sediment control, equipment fuels and lubricants control and air pollution control. In a study on outsourcing firms in the Malaysian electrical and electronics (E&E) industry, reference [21] concluded that the offshore outsourcing sales is positively influenced by the level of Corporate Social Responsibility (CSR) practices, the outsourcing firms are capable in handling customers’ CSR demands and the government plays an important role shaping CSR activities. Reference [22] reviews the cement manufacturers in Malaysia and it was found that these heavy industry companies that are associated with significant environmental impacts and high occupational safety and health risk hazards have implemented environmental management system. Reference [23] determined the emergency preparedness and response plans of the hazardous material transportation companies and the results revealed that these companies did not have a proper management system of safe transportation, had inadequate training of personnel, and the transport vehicles were not provided with appropriate tools and equipment for emergency response.

III.

METHODOLOGY

There is a need to assess on management practices of measuring environment, occupational safety and health performances of Malaysian companies as the importance of ESH is not much emphasized. In the literature, there has been wide coverage on the implementation of EMS and OHSMS in the construction and engineering services sectors, and availability of industry standards in petrochemical sector and the author has also studied into the system implementation of cement manufacturers, hence this paper will focus on recycling companies. There is a learning curve for the companies to facilitate the adoption of the management systems. To adopt EMS and OHSAS management systems i.e. the environment, occupational safety and health (ESH) elements, it may be necessary to have corporate cultural changes that support

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

complex operational activities to achieve defined ESH objectives and targets in line with the commitment of the ESH Policy and regulatory-compliant. Relying on evaluation on these critical international standard elements, the study highlighted the empowerment of employee through the Safety and Health Committee or internal auditor team, and employee participation in decision-making. Comparisons of environmental policy statements and environmental management systems adopted by the companies were also made. This paper shows how the companies were adjusted to the ISO 14001 and OHSAS 18001 requirements. This paper discusses implementation of the management systems towards development of environment protection and OSH culture. Identification of environmental aspects is essential to reduce the impacts. Control measures are such as solid waste and scheduled waste control and pollution control. IV.

Recovery and Winner Global Metal, the OHSAS 18001 certified companies are CCM Chemical, IRM, Jaring Metal Industries, Kimia Zue Huat, Kualiti Alam, Reclaimtek and Shan Poornam Metals, while the ISO 9001 certified companies are Aldwich Environ-Management, CCM Chemical, High Cans Corporation, IRM, Jaring Metal Industries, Kimia Zue Huat, Kualiti Alam, Malay-Sino Chemical Industries (MSCI), Meriahtek, Ming Engineering Plastic (MEPSB), Natural Arrangement (NA), Reclaimtek, SPM Oil and Gas, Tai Kwang Yokohama Battery Industries, and Victory Recovery.

RESULTS AND DISCUSSION

With the restriction in transporting scrap materials to other countries that comply with the Basel Convention in early 1980s, off-site processing, recovery and recycling facilities began to flourish in Malaysia. Recycling companies’ provide services to industry to reclaim valuable materials for reuse and maximize the utilization of these resources that provide savings in energy and raw materials, all of which reduce industry's impact on the environment. Recycling brings cost effective alternatives to landfill disposal. These recycling companies assist the industry to reduce, reuse, recycle, compost or dispose, and together work towards a better environment. The recycling companies play an important role in environmental recycling programs. Recycling companies press carton scrap to bundle and sent as raw material to produce tissue at tissue factory; wood factory reuses woods for making crates from wood scrap; plastic recyclers pack plastic waste either by compressing into bundles or re-producing to plastic parings by crushing as raw material to manufacture construction pipes; recyclers reprocess construction and demolition debris; and glass factories recycles used glass. SPM Oil and Gas claims to be Malaysia’s biggest exporter of recycled non-ferrous metals and plastics. As of 6th July 2009, there are a total of 244 scheduled waste recycling and recovery companies in Malaysia, which are mostly (68.9%) found in West Coast of the Malay Peninsular, precisely 22.5% located in Selangor, 21.3% in Pulau Pinang, 14.8% in Johor, 10.2% in Perak, and the rest in other states as shown in Fig. 3 [24]. In terms of license issued, of the total of 346 licenses, majority (36%) is of the category of electronics waste (E-Waste) with scheduled waste code SW 110. Out of these contractors, information of 44 companies, mostly from more established contractors is found in public domain. The companies are certified by QMS (15), EMS (19) and OHSMS (7). The ISO 14001 certified companies are Alam Aliran Kualiti, CCM Chemical, Excelbond Metal Recycling Industries, IRM, Jaring Metal Industries, Kuality Alam, Meriahtek, Ming Engineering Plastic, Natural Arrangement, Primochem, Reclaimtek, SGT Metal, Shan Poornam Metals, SPM Oil and Gas, Techom Metal Recycle, Texcycle, Victory

Figure 3. Number of recycling companies by state Source: List of Scheduled Waste Contractor (Department of Environment)

Due to the nature of the recycling industry which is environmental related, and the characteristics of the materials handled which is hazardous, the study investigated the environmental and OSH reporting practices of 44 recyclers in Malaysia. The findings indicate that 16 recyclers have implemented any form of published environmental and OSH reporting. The findings indicate that three recycling companies [Texcycle, CCM Corp. (subsidiary CCM Chemical), UEM Environment (subsidiary Kualiti Alam)] of Bursa Malaysia listed recycling company or parent company of recycling company have implemented comprehensive published environmental or OSH or social responsibility or sustainability reporting. Recycling is an environment business therefore EMS implementation is to improve efficiency thus profitability. Majority of the recyclers are primary or secondary ferrous metals (iron and steel) and nonferrous / precious / rare earth metals (e.g. aluminium, copper, zinc, nickel, solder, gold, silver, platinum, titanium and high temperature metals / alloys) processing or recycling plants. The scrap metal are processed through dismantling, containing, gravity separator, sorting / segregating separator, crushing, shredding, chip grinding, shearing or cutting, baling, briquetting or chopping, blending, settling, compacting, packing, palletizing using mechanical, chemical stripping and electrolysis processes (for precious metal recovery), and thermal treatment with (for aluminium and solder recovery). Cables are recycled as medium grade copper flakes (clove) granulation production.

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

These metal-bearing parts and dross are then sent to recovery plants for further process to obtain products such as tin ingots. Aluminium is recycled as aluminium flakes. Secondary steel plates can be produced. These materials are redistributed for recycling by electric arc furnace mills, integrated steel mills, foundries, secondary smelters for recovery / refining / reclamation / casting process involving machinery and chemical usage i.e. remelting into new metallic products. To maintain accuracy and integrity, the recycling companies can equip DOE approved laboratory facilities such as atomic absorption spectrometer (AAS), inductively coupled plasma (ICP), optical emission spectrometers, high temperature melting furnaces, and ultra violet analyzer. Other recycling activities includes display monitor recycling companies that recover television / computer cathode ray tube (CRT), Liquid Crystal Display (LCD) monitor and fluorescent lamp for manufacture monitors. Waste oil recyclers recover material by converting the base oil (waste engine crankcase motor oil and gear oil from workshop and service station, ship engine oil from dock yards, thermal oil, transformer oils, lubricating oil, mineral oil, dielectric fluids used in transformers, and capacitors from industrial application, and spent catalyst) to gasoil or medium fuel oil, a blend of gasoil and heavy fuel oil, with less gasoil than intermediate fuel oil. Conventional method to recover base oil is thermal inductive centrifuge. Recently, there is waste oil to diesel plant (WODIP) established in Malaysia, which is third of its kind in the world. The process converts the base oil to gasoil ensures that waste oil is effectively converted and distilled into clean reusable high value gasoil. Products derived from processing waste oil are such as diesel, naphtha, HFO, benzene, kerosene and asphalt extender. A Catalyst Recovery Unit (CRU) plant utilizes pyrolisis technology (pyro metallurgy) or the thermal oxidation process that enables the CRU to recover from the spent catalysts in the form of usable base metals such as copper, zinc, and nickel as well as precious metals such as platinum, palladium, rhodium and silver. Metal hydroxide sludge from wastewater treatment plant can be recovered, and can also be used as raw material in cement manufacturing plant. Purification of solvents uses various chemical mechanical (distillation) process treatments for publication and treatment. Contaminated container or rag recyclers clean contaminated metal or plastic drums and rags for reuse or recycle. Recovered materials can be converted into industrial products such as floor mats and spill absorbents. Latex recyclers collect manufacturers sensitive rejects and scrap, crush and reprocess into high quality rubber gum. Conventional rubber recycling reclaims rubber using heat (Autoclave) technology which degrades the rubber to about 50% of its original properties with toxic effluence being discharged. Some recyclers use unique process of depolymerization that involve a combination of chemical and mechanical process without using heat that does not cause the degradation of the rubber properties. Chemical recyclers recover acid and alkali waste through neutralization process. One of the recycler, TOR Minerals’ produces titanium dioxide

pigments. Gypsum waste is processed for gypsum and plaster products. A used-battery recycling plant that uses reclamation technology to recover lead which has been approved by the UN Environmental Department internationally. Recycling processes of selected material are as shown in Fig. 4.

Figure 4. Recycling processes by selected material

A. Commitments: General Requirements and Policies The standards require that the organization to establish and maintain the management systems. The policy is a statement of an organization’s intentions and principles in relation to its overall environmental / OSH performance. According to the standard, the policy must be appropriate to the nature, scale and environmental impact and / or OSH risks of the organization’s operations, products or services, properly documented and implemented. The companies through these environmental policies commit to preserve the environment, prevent pollution and reduce impact to environment; the OSH policy should promote healthy and safe working conditions to prevent injury and ill health that the employees are free from risks during operations. The policy provides a framework for the management system objectives and targets. The policy should ensure that activities are conducted with full compliance of all applicable legislation requirements and other requirements to which the companies subscribe. The policy should also continuously review to assess the environmental impact and commit to continual improvement. All employees are trained to the highest environmental and OSH standards. The employees, suppliers, contractors, visitors and public are informed of the company's policies towards environment, occupational safety and health. Content of policy statement is examined by scoring means scores given when relevant words or phrases are available in the policy statement. Among ten companies for which the environmental or occupational safety and health policy is available, half of these companies (five) scored 7, three companies scored 6, one company score 5 and 4 respectively as shown in Fig.5. Hence, it is found that the commitment from the top management is rather high.

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

TABLE II. SIGNIFICANT ENVIRONMENTAL ASPECTS AND IMPACTS Environmental Aspects Environmental Impacts

Figure 5. Score of ESH policy

B. Planning 1) Hazard Identification, Risk Assessment and Determination of Control (HIRADC) and Environment aspect identification An aspect is any element of an organization’s operations, products or services that might interact with the environment. The difference between ISO 14001 and OHSAS 18001 standards is emphasis on environmental aspect/impact studies for the former and HIRARC for the latter. The standard requires a systematic approach to assessment of all aspects therefore even trivial ones must be considered. A comprehensive review should be conducted to review the facility and its processes to identify environmental aspects in order to identify the significant environmental impacts and liabilities. Environmental aspects need to be quantified using rating of legislation, public opinion, economic impact, severity and potential for occurrence, etc. A list of environmental aspects for the facility as well as for suppliers and products has to be developed. OSH risk assessment needs to assess both workplace and lifestyle risks, where the occupational safety and health hazards need to be assessed and quantified using risk matrices. OSH tool must also take into account planning of maintenance operations, risks relating to workers’ performance in non-routine operations, and contractor management. OSH hazards have to be control following the hierarchy of elimination of hazards, substitution, engineering controls (e.g. enclosure), administrative controls and personal protective equipment (PPE). Significant environmental aspects and impacts in the recycling industry include depletion of natural resources (utility and chemical), air pollution (drum washing), smell / odor and noise (recycling processes), groundwater pollution (recycling processes), water pollution (wastewater), global warming (refrigeration using ozone depleting substance, ODS), carbon dioxide (green house gas, GHG) emission (logistics) and chemical spill (emergency situations) as summarized in Table II.

Utility Usage

Depletion of natural resources

NaOH used at WWTP

Depletion of natural resources

Drum washing

Air pollution

Recycling processing

Smell / Odor

Recycling processing

Noise

Building and operations

Groundwater Pollution

Wastewater

Water Pollution

Recycling processing

Scheduled waste

Refrigeration

Global warming (ODS)

Logistics

CO2 (GHG) emission

Emergency situations

Oil / Chemical spill

Occupational safety and health hazards are in terms of physical such as noise and vibration, heat, radiation – infra-red (IR) and ultra-violet (UV), electricity such as high voltage machinery, ergonomic such as slips and fall, flying objects, entanglement, cuts, burns, scalding, lifting heavy object, prolonged standing, poor posture; chemical such as mineral dust – silica and detergents; biological such as viruses Hepatitis B, HIV, SARS, Influenza A (H1N1); bacteria tuberculosis (T.B.); psychological such as work overload (extended overtime) and stress as summarized in Table III. TABLE III. OCCUPATIONAL SAFETY AND HEALTH HAZARDS Type of Hazard Health Effect Processes PHYSICAL Noise & vibration, Deafness, Heat stress / Dismantling, Blasting, Heat, Radiation – Infracramp, Cataract, Molten metal, furnace Red, Ultra-violet Conjunctivitis, Keratitis ELECTRICITY High voltage Death Main power supply machinery ERGONOMIC Slips and fall, Flying Temporary and Operations (Crushing, objects, Entanglement, Permanent disabilities, Dismantling), WWTP Cuts, Burns, Lifting Backache, Fatigue and heavy object, muscle pain, Sprain Prolonged standing, Poor posture CHEMICAL Mineral dust – silica, Pneumoconiosis, Skin Raw material area, Detergents disease Tumbler BIOLOGICAL Viruses (Hepatitis B, Pulmonary TB, Hygiene HIV, SARS, A affected lymph nodes, (H1N1)), Bacteria: Death Tuberculosis (T.B.) PSYCHOLOGICAL Work overload Heart disease, Burnout, Shift work, Night work (extended overtime), Violence Stress

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

2) Legal and Other Requirements For environment, related legislation to comply is mainly EQA 1974 and its subsidiary regulations such as Environmental Quality (Clean Air) Regulations 1978, Environmental Quality (Sewage and Industrial Effluent) (SIE) Regulations 1979, and Environmental Quality (Scheduled Waste) Regulations 2005. For occupational safety and health, related legislation includes Factories and Machinery Act (FMA) 1967 and their subsidiary regulations such as FM (Noise Exposure) Regulations 1989 and Occupational Safety and Health Act (OSHA) 1994 such as Occupational Safety and Health (Control of Industrial Major Accident Hazards) (CIMAH) Regulations 1996, OSH (Classification, Packaging and Labeling of Hazardous Chemical) (CPL) Regulations 1997, OSH (Use and Standards of Exposure of Chemicals Hazardous to Health) (USECHH) Regulations 2000 and Occupational Safety And Health (Notification Of Accident, Dangerous Occurrence, Occupational Poisoning And Occupational Disease) (NADOOPOD) Regulations 2004. In order to share industry best practices, recyclers may join as a member of the International Association of Electronic Recyclers. Chemical companies can subscribe to the principles of Responsible Care, an international initiative built around guiding principles and codes of management practices that reflect the chemical industry’s obligation to the public for the responsible management of chemicals and continuous performance improvement in occupational safety, health and environment. Some of these recyclers have formed association for the interest of the industry. The Association of Scheduled Waste Recyclers (ANSWERS) consists of Hazardous Municipal Solid Waste (HMSW) recyclers, provide the opportunity for the scheduled waste contractors to interact with the regulatory agents and communicate to the regulators on the issues faced by the scheduled waste contractors. The Industrial Waste Contractors’ Association (SOWACO) is made up of solid waste contractors located in Selangor and the Federal Territory. SOWACO was formed in 1995 with 16 members, comprising of the companies using the hook-lift system with detachable containers, specifically to service factories. The objective of SOWACO is to improve professionalism of solid waste service providers. 3) Objectives, Targets and Management Program(s) The objectives and targets are established after significant aspects identification where all significant aspects are considered with the numbers of broad objectives has to be reasonable, and supported by targets by implementing an environmental friendly recycling system and maximize the usage of environmental depleting resources. The programs are designed to provide the means to deliver objectives and targets on a timely basis, and minimize of any adverse impact on the environment and OSH by continuous improvement of ESH performance such as equipping the plant with the latest range of high efficiency machinery and equipment for environmentally sensitive and responsible processes. The companies invest in technology that can improve the design of furnace and environmental equipment, develop new techniques and processes to reach even higher standards of

treatment and efficiency, have continuous improvement in facility upgrading from time to time and use the most effective, modern and innovation environmental-friendly method in metal recycling. Depletion of natural resources in utility usage is controlled by effective utilization of energy, replacing fuel oil with natural gas, reduce consumption of liquefied petroleum gas (LPG) in drying process by increasing drying efficiency, by avoiding half-load tumbler, reduce sludge moisture content by using hydrated lime as agent in drying process, use of renewable energy alternatives such as solar energy using solar panels to provide hot water for washing process and reuse wastewater in recycling process. Depletion of natural resources such as sodium hydroxide (NaOH) used at WWTP is reduced by planning control to minimize usage. Controlling of air pollution by wet scrubber, and monitoring of volatile organic compounds (VOC), total organic carbon (TOC), total suspended particles (TSP), sulfide oxide (SOx), nitrogen oxide (NOx) and carbon monoxide (CO) emission. Smell or odor is controlled by introduction of waterborne paints to achieve the objective of reduction and deployment of VOC emissions detector. Noise from recycling processes is minimized by noisy machinery enclosure and provision of PPE (ear plugs / mufflers) to keep below 85 dB(A) action level. For carbon dioxide (CO2) greenhouse gases (GHG) emission of logistics, the companies reduce carbon footprint such as getting LPG from nearby supplier, truck fleet planning: maximize load for each route, Regular truck fleet maintenance and biodiesel made of used cooking oil as fuel for trucks. Water pollution can be controlled with approved wastewater treatment facility by the Department of Environment (DOE), monitoring to control effluent quality of suspended solids (SS), biological oxygen demand (BOD), chemical oxygen demand (COD), oil and grease (O&G), and heavy metals meeting SIE regulations, using water treatment technologies such as filtration, ultrafiltration, reverse osmosis, deionization (demineralization), ozonation and disinfection. Scheduled waste from recycling processes is controlled by application of innovative waste treatment solutions and sustainable practices. Waste segregation is practiced where all disposal of paper, carton boxes, aluminium and glass are sent for recycling. Dust from aluminium recovery process can be used as fertilizer (contains calcium and potassium) or catalyst for steel mill. Sludge scheduled waste separated from wastewater through chemical reaction is compressed and dried, conversion of sludge into renewable energy or industrial products such as mixture with compost and soil for plant growth and oil absorbents. Disposal to approved contractor Kualiti Alam for incineration and subsequently landfill. Solid waste disposal is controlled such as application of starch degrading technology plastic bags. Wherever possible, recycle materials used within own company function. To prevent groundwater pollution from building and operations leakage, the factory could be constructed with 8” depth concrete floor layer in additional to designated containment bund. Global warming can be minimized with prohibited use of ozone depleting substances (ODS) in refrigeration.

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

TABLE IV. ENVIRONMENTAL MANAGEMENT PROGRAM Environmental Control Impacts Depletion of Effective utilization of energy by replacing fuel oil with natural natural gas. Reduce consumption of LPG in drying process resources in by increasing drying efficiency by avoiding half-load utility usage tumbler. Reduce sludge moisture content by using hydrated lime as agent in drying process, instead of electricity. Renewable energy alternatives: Solar energy using solar panels to provide hot water for washing process. All wastewater is reused in production. Depletion of Planning control to minimize usage. natural Dilution at supplier premise. resources of NaOH Air pollution Equipped with an air scrubber for pollution control. from drum Wet scrubber: Monitor VOC, TOC, TSP, SOx, NOx, CO. washing Smell / Odor Introduction of waterborne paints to achieve the objective of reduction. VOC emissions detector. Noise from Enclosure of noisy machinery. recycling PPE (ear plugs / mufflers) to keep below 85 dBA action processes level. CO2 (GHG) Reduce carbon footprint: emission of Source LPG from nearby supplier. logistics Truck fleet planning: maximize load for each route. Regular truck fleet maintenance. Biodiesel from used cooking oil as fuel for trucks. Solid Waste Starch degrading technology plastic bags. Disposal Plastic bags use for storing, collection and delivery of contaminated material. Wherever possible, recycle materials used within own company function Scheduled Innovative waste treatment solutions and sustainable waste from practices. recycling Waste segregation is practiced where all disposal of paper, processes carton boxes, aluminium and glass are sent for recycling. Dust from aluminium recovery process can be used as fertilizer (contains calcium and potassium) or catalyst for steel mill. Sludge scheduled waste separated from wastewater through chemical reaction is compressed, dried Convert sludge into renewable energy or industrial products such as mixture with compost and soil for plant growth and oil absorbents. Disposal to approved contractor (KA) for incineration and subsequently landfill. Water pollution Operations with the Department of Environment (DOE) approved wastewater treatment facility. Effluent quality monitoring for SIE regulations: SS, BOD, COD, O&G, heavy metals The water treatment technologies are such as filtration, ultra-filtration, reverse osmosis, deionization (demineralization), ozonation and disinfection. Global Prohibited of use warming if ODS is used in Refrigeration Groundwater 8” depth concrete floor layer. Pollution from Containment wall / bund. building and operations leakage Emergency EPR SOP / ERT personnel / material spill

These companies have identified emergencies such as fire, explosion, burn caused by molten metal from furnace, chemical spillage and ready with SOP for response plans started with awareness training, and emergency response team (ERT) formation, implemented in routine with fire management tested with drills as summarized in Table V. TABLE V. EMERGENCY RESPONSE PLAN Hazards

Control

Fire, explosion

EPR drill, fire safety awareness, fire management plan

Burn cause by furnace molten metal

SOP, protective work clothing

C. Implementation and Operations 1) Structure and Responsibilities. Roles, responsibilities and authorities have to be defined, documented and communicated. Top Management has to provide essential resources for implementation of the system to demonstrate commitment to environment and OSH program. Top Management assigns a management representative that is responsible for and has authority for managing ESHMS implementation and maintenance and reporting to top management. 2) Training, Competence and Awareness The standard requires all personnel whose work may have a significant environmental impact to have appropriate training with associated record documented and kept current. The employees must maintain a high standard of environmental and OSH awareness. Intensive training sessions are conducted to alert the employees on the safest way to conduct their duties. Provision of training for new recruits with orientation, waste management, emergencies, responsibilities, for operation staff with legal requirements, OSH (CPL) 1997, OSH (USECHH) 2000, EQ (SW) 2005, SOP, PPE usage, emergency drills (usage of fire extinguisher against fire, chemical spillage), for driver with OSH (CPL) 1997, OSH (USECHH) 2000, EQ (SW) 2005, PPE, emergency drills, for administration staff with ESH requirements, efficient energy, etc. Training can also be conducted by externally such as driver chemical handling training by NIOSH, production staff gas leakage inspection and measures training by gas supplier, production staff chemical handling by chemical supplier CCM and other ESH training by customers. 3) Communication, Participation and Consultation Internally, these companies establish safety and health committees to for employee participation in decision making such as incident investigation, on top of other means of communication and consultation such as ESH suggestion schemes, ESH newsletter and ESH Week / Campaign. For community, the companies publish ESH report, social responsibility report, sustainability report, and organize safe school and road safety campaign, environmental camp or environment awareness programs for school / suppliers / contractors / NGO / public.

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

4) Management system documentation Each requirement of the standards should be addressed by appropriate procedures. There are three levels of procedures, system manual, company procedures that encompass across departments and work instructions that are process specific. 5) Document and Data Control The method for establishing, approving, changing, maintaining, replacing, and distributing documents have to be defined. Documents are revised in a timely fashion and receive the required approvals. The most recent revision of documents has to be available. The document and data could be stored in hard copy or electronically. 6) Operational control Safe working practices have to be fully integrated into the business operations. Hazard communication is required to those who work with the risk. Job Hazard Analysis (JHA) is carried out prior to commencement of a job. A procedure covering chemical handling may include update of material safety data sheets (MSDS). Scheduled waste trucks shall avoid densely populated area. The employees must be trained on relevant Personal Protective Equipment (PPE) Management program. Activities of related parties such as vendors and customers are advised in the transportation, storage and disposal of hazardous wastes. 7) Emergency Preparedness and Response (EPR) Potential emergencies include fire and explosion may due to contaminated rags / wipes / gloves containing solvent or gas leakage, land and water contamination from chemical spillage or contaminated water spillage from the processes, or due to the spillage of scheduled waste during transportation. Other types of potential disasters range from structural collapse, landslides, biological to meteorological incidents. Companies must be ready with emergency and crisis management plan to response with first aid and emergency measures such as firstaid kits, first-aid room and emergency response team (ERT). D. Checking and Corrective Actions 1) Performance measurement and monitoring The performance measurement system measures the company's performance against the standards. ESH indicators are monitoring on utility such as electricity and LPG used in drying process, diesel consumption in trucks, generation of scheduled sludge waste. The OSH performance of employees is evaluated e.g. dangerous occurrences, recordable cases, reportable rate, lost time injury (LTI) and fatality rate monitoring and health surveillance. OSH in trucks is the key to the way conducting recycling business therefore OSH performance key indicators during transportation such as reportable accidents, dangerous occurrences and speeding are monitored. 2) Incidents, Non-Conformance, Preventive and corrective action

Work-related injuries, ill health, diseases and incidents are investigated for their impact on occupational safety and health performance, analyzed and discussed to prevent recurrences. 3) Records and Records Management The companies have to keep objective evidence of the management systems. The records are such as management reviews minutes, training record, supplier evaluation record, calibration record, internal audit record, non-conformance record, corrective action record and preventive action record. 4) Audit Safety inspection / audits and assessments are conducted regularly to measure the OSH performance and to ensure that the management system is being used properly. Customer visits or audits can also determine if the management systems are established, implemented and maintained. E. Evaluation and Action for Improvement: Management Review The driving force for continual improvement comes from management reviews which examine how well the management system has worked, how well objectives have been met and what changes are needed. These meetings are attended by top management and the implementation team. V. CONCLUSIONS Larger recycling companies are found more environmentally conscious and safety concern and OSH is being managed in workplaces where certification is being carried out. Among environmental and safety best practices are policies, programs, rules and practices, and safety campaigns. The responsibilities for environment and health and safety have to be integrated throughout in the organizational culture at each function and level. ESH implementation helps to build a better partnership between three main stakeholders namely government, local citizens and companies. In development country like Malaysia, where safety or security is still remains at an unsatisfactory level, high however embedded high-risk technology such as nuclear power generation may not be suitable to be adopted at the current development level yet. Pollutants and workplace safety have been found better managed. Regulated industries such as recycling companies are expected to implement the EHSMS in order to maintain their competitive edge in the global market place. Export-oriented firms should take advantage of the EHSMS as they could benefit from the implementation of the standards through improved efficiency, safer workplace and new market potential. Competitive advantages can be achieved with synergy between environment and safety as well as more focus on continuous improvements. Furthermore, this expands the focus of the systems to include the whole product chain, which also corresponds to a similar focus in Corporate Social Responsibility.

3rd INTERNATIONAL CONFERENCE ON ENERGY AND ENVIRONMENT, Malacca, Malaysia, 7-8 December 2009

VI. REFERENCES [1] [2] [3]

[4] [5]

[6] [7] [8] [9]

[10] [11]

[12]

[13]

Selected Social Statistics Series 10. Department of Statistics. May 2009. Checked 1 June 2009. http://www.statistics.gov.my Labor and Human Resources Statistics (Various). Ministry of Human Resources. Checked 16 June 2009. http://www.mohr.gov.my List of Safety and Health Officer recognized by DOSH in Malaysia, Senarai Pegawai Keselamatan dan Kesihatan (SHO) yang Telah Diiktiraf oleh JKKP di Malaysia. Department of Occupational Safety and Health. Checked 20 July 2009. http://www.dosh.gov.my DOSH issued 5,559 notices, JKKP keluar 5,559 notis. Harian Metro. 21 May 2009. Practices of Occupational Safety and Health Culture, Amalan Budaya Kerja Selamat dan Sihat. Department of Occupational Safety and Health. Checked 20 July 2009. http://www.dosh.gov.my Annual Reports (Various). Department of Environment (DOE). Checked 14 May 2009. http://www.doe.gov.my Do-It-Yourself (DIY) Schemes. Construction Industry Development Board (CIDB). Checked 12 May 2009. http:// www.cidb.gov.my/ ISO certification to avoid negligence, Pensijilan ISO elak kecuaian. Berita Harian. 15 June 2009. E. R. Pedersen, “Introduction. Corporate Citizenship in Developing Countries – New Partnership Perspectives”. In: Pedersen, E.R. and M. Huniche (eds) Corporate Citizenship in Developing Countries. New Partnership Perspectives. CBS Press: Frederiksberg, 2006, pp. 7-25. Accredited Certification. Department of Standards Malaysia (DSM). Checked 12 May 2009. http://www.standardsmalaysia.gov.my Junaini Mohamad and Zauwiyah Ahmad, “Determinants of environmental reporting in Malaysia, A Positive Accounting Approach”, 3rd Conference of Asian Academic Accounting Association (FourA), 2728 October 2002. S. Iavicoli, B. Rondinone, A. Marinaccio and M. Fingerhut, “Research Priorities in Occupational Safety and Health: A Review”. Industrial Health. Vol. 44, 2006, pp. 169-178. G. Wilkinson, and B.G. Dale, “Management system standards: The key integration issues”, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 214(9), 2000, pp. 771-780.

[14] R. Ziebell, “Unified approach to compliance management”. Proceedings of the 1999 ASQ’s 53rd Annual Quality Congress, Anaheim, CA, USA, 1999, pp. 158-165. [15] R. Holdsworth, “Practical applications approach to design, development and implementation of an integrated management system”. Journal of Hazardous Materials, Vol. 104(1-3), 2003, pp. 193-205. [16] T.H. Jørgensen, M.D. Mellado, and A. Remmen, “Integrated Management Systems”, Working Paper 7, Department of Development and Planning, Aalborg University, 2004. [17] Abdul Rahim Abdul Hamid, Bachan Singh, Wan Zulkifli Wan Yusof, Andrain King Tzee Yang, “Integration of Safety, Health, Environment And Quality (SHEQ) Management System in Construction: A Review”, Jurnal Kejuruteraan Awam, Vol. 16(1), 2004, 24-37. [18] Simon Laddychuk and Rio Tinto Alcan, “Paving the Way for WorldClass Performance”, Journal of Safety Research, Volume 39 (2), 2008, pp. 143-149. [19] A Bakri, M Zin, MS Misnan, AH Mohammed, “Occupational Safety And Health (OSH) Management Systems: Towards Development Of Safety And Health Culture”, Proceedings of the 6th Asia-Pacific Structural Engineering and Construction Conference (APSEC 2006), Kuala Lumpur, Malaysia, 5 – 6 September 2006. [20] Tuan Fadzilah T.S., and Noor Zalina Mahmood, and Che Rosmani Che Hassan, “A Study on Identification of Significant Environmental Aspects and Impacts of Piling and Foundation Works”. Malaysian Journal of Science, Vol. 27 (1), 2008, pp. 47-59. [21] Sabrina Y.C. Chong, and P. Wad, “Sustainability through state-driven corporate social responsibility? The case of outsourcing firms in the Malaysian electrical and electronics industry”, Presented in International Conference on Public-Private Partnerships in Development, 15 - 16 January 2009. [22] H.N. AuYong, “Motivation to Adoption of ISO 14001 Environment Management System”. The 14th International Conference of Thinking (14ICOT), Kuala Lumpur, UPM, 22~26 June 2009. [23] M.S. Aini, A. Fakhru’l-Razi, M. Daud, W.M.N. Ibrahim and S.K. Tangavelu. “Study on emergency response preparedness of hazardous materials transportation”. Disaster Prevention and Management. 10: 3 (2001) pp. 183-188. [24] List of Scheduled Waste Contractor in Malaysia. Department of Environment (DOE). Checked 6 July 2009. http://www.doe.gov.my

Suggest Documents