Executive Summary
Noor Paper Arts (NPA) is engaged in the manufacturing of handmade paper, which is an eco-friendly product. The handmade paper manufacturing process requires plenty of water and considering this aspect, the manufacturing facility was based at Jebel Ali Free Zone. Its factory is located in Jebel Ali Free Zone. Even though the company is doing a good job by promoting eco-friendly paper products, the situation inside its manufacturing facility is alarming. The workers do not follow any safety or precautionary measures and as such, are prone to several risks and hazards.
The process being followed during paper manufacturing is primitive and outdated machines are being used. The raw material is not of good quality that has dust and other foreign particles in it. The positioning of motors is not safe and their belts are worn out. There is no provision of masks for the workers who work in dust and deal with hazardous chemicals. The manufacturing facility does not have a sufficient number of fire extinguishers. Moreover, there is no fire exit in the shed. The floor is wet due to water spillage. Tanks are kept open that pose a risk of workers falling into them. Machines are handled manually and there is a risk of the workers getting caught in them. Workers even smoke within the factory premises, which can lead to a fire.
A little care and investment can help in getting rid of all such problems. Inspection of the factory premises and the manufacturing process were conducted by competent personnel of the company. This report contains the observations of the inspection. Recommendations based on these observations are also included in the report.
Introduction
This report is a result of the rigorous inspection of the manufacturing facility of NPA that was conducted on 15th September 2014. The motive behind this inspection was to ascertain that all the required safety measures were being followed. The inspection also aimed at identifying potential discrepancies and drawbacks in the manufacturing process and the installed machinery/equipment. It was conducted by the companyâs âHealth and Safety Officerâ and his subordinates.
The factory has a workforce of 150 skilled, 200 semi-skilled, and 100 casual/unskilled people. The work is carried out in three shifts; the night shift workers are given some extra payment. The business activity includes manufacturing handmade paper and various gift products made out of it. The raw material used is hosiery waste.
Main findings
NPA has more weaknesses than strengths as far as complying with the UAE governmentâs guidelines is concerned. The strengths include its being eco-friendly product-based industry and water conservation. Among the weaknesses, where government guidelines are breached, the following are the major ones:
Risk of the respiratory problem â observations 1, 6, and 16
The UAE Labour Law (Article 19) has strict guidelines for employers regarding occupational diseases. In the handmade paper-making process, there are certain areas where the operators and other laborers are prone to respiratory problems. This is due to the dust that emanates from the hosiery waste (cotton rags) and chemicals. Such instances can be avoided by taking a little extra precaution and requesting the vendors also to send better quality hosiery waste that is free of dust. There is no additional cost involved in following such precautions and as such, there should not be any problem or hindrance (such as approval from the management or board). For hazardous chemicals, airtight containers should be procured for storage purposes. This would cost around 1000 dirham.
Risk of falling from height and/or slipping on the floor â observations 9, 10, 12 & 13
Handmade paper making is a labor-intensive industry. As such, during the manufacturing process, to reduce the use of machines, the beater is installed at a height so that the pulp can flow into the storage tanks by way of gravity. At the same time, a lot of water is used during the beating process. As of now, the water spillage cannot be controlled (due to certain shortcomings and lack of proper technology in this industry), which leads to wet steps and floors.
During ascending and/or descending the steps, the operators and other laborers are prone to falling from height. This might be a cause of bone injuries. It is worth mentioning that Article 13 of UAE Labour Law has a provision for employersâ prosecution in case of injuries to employees during work hours.
Since water spillage cannot be controlled (as of now), the best thing that can be done is to depute the required number of workers for sweeping the floor and keeping it as dry as possible. This particular step would cost only the wages of the deputed people. Considering the size of the shed, two workers in every shift should be enough to take care of the issue. Three shifts mean six workers. On average, the monthly salary of six workers would be six to seven thousand dirhams. Another alternative could be to replace the floor surface with anti-skid tiles. This would cost around 20,000 Dirham and would be a one-time investment.
Risk of noise pollution â observation 8
In the complete handmade paper-making process, the rag chopper is the only machine that makes a lot of noise. There is no way to stop this noise because the process involves steel blades rubbing against each other. The only precaution that can be taken is to provide the operators and other laborers with appropriate preventive aids such as hearing protection devices. Purchasing such devices should not cost more than 5,000 dirhams. This would be a recurring investment (every six months). It should be noted that Article 54 of the UAE âFederal Law # 24 of 1999 for the Protection and development of the Environmentâ has prescribed certain limits for noise levels by machines and other equipment.
Fire risk â observations 7, 24 & 29
Since the factory is situated in Jebel Ali Free Zone, it comes under the jurisdiction of Ports, Customs & Free Zone Corporation (PCFC). All businesses that come under PCFC have to adhere to the âHealth, Safety & Fire Protection Regulations & Standardsâ laid out by the Dubai government. There are a couple of instances at NPA that are related to fire risk. First of all, the fire extinguisher is not calibrated. Secondly, laborers have the habit of smoking inside the shed. Finally, there is no separate fire exit. Making provision for a fire exit would incur expenses that might amount to 5,000 dirhams.
Risk of electrocution â observations 5 & 11
The motor of the rag chopper and the agitator pump are kept open. This could lead to the operator getting entangled in the motor v-belts, which might be a cause of electrocution and/or fatal injuries. The motors should be shifted to a safe place (probably a corner) and covers should be provided. Shifting the motors would cost around 2000 dirham and providing covers would amount to an additional 1000 dirham. According to Article 96 of UAE Federal Law # (8) of 1980, all businesses must take precautionary measures to prevent hazards about electricity.
Conclusion
This report brings forward certain issues that need immediate attention. The worst drawback in the factory is non-compliance with safety measures. The main findings suggest that several areas/processes need to be rectified. The major issues are related to health hazards such as respiratory problems, fall injuries, noise pollution, fire risk, and electrocution. Though these issues are very significant, rectifying them would need just a little care.
Workers working in areas where a lot of dust emanates from the process do not wear any face masks to protect themselves from inhaling it. The floor is wet and can be a cause of severe fall injuries. Certain machines make a lot of noise and the operators do not have any hearing protection device to put on. The factory shed does not have any fire exit, which can prove to be fatal during times of emergency. Electric motors and pumps are kept unguarded and can cause electrocution.
The report includes some recommendations that should help improve the working conditions and safety of the workers. Such measures will surely increase the workersâ trust in their organization, which is bound to increase productivity.
Recommendations
Management Report
Hazards.