Designing and Engineering Occupational Health and Safety in the Workplace.pdf

Designiing and Engineering OHS

1. Design and Engineering
Occupational Health and
Safety in the Workplace
An overview of the key principles and best practices for ensuring a safe and healthy
work environment through effective design and engineering.
Prepared by : Ir. Tjoek Oedowo, ST, MH, CLAP, IPM, ASEAN Eng
25 years experience in Chemical Industries; 9 Years Consultant ISO(s), Journey Risk Assessment
hazardous chemical, Crisis Management , PHA Leader Austrian Standard ; SMK3, Environmental;
Director PJK3 Kemnaker & BNSP; Consultant for fulfillment government regulations & laws
especially for disaster and Emergency (Minister of Manpower, Minister of Industry& Minister of
Environmental & forestry) for Chemical/Petrochemical Industry/Energy/Manufactures
Extraordinary lectures for UNDIP and UGM
Mata Kuliah
Design dan Rekayasa K3

2. “Safety is not a cost, but an investment in productivity
and quality management.”
W. EDWARDS DEMING

3. Introduction to Occupational Health and Safety
•Workplace Safety
•Regulatory Compliance
•Productivity
•Risk Management in Process Safety and
Personal Safety
•Cost Savings

4. Key Principles of Occupational Health and Safety
•Hazard Identification and Risk Management
•Worker Participation and Engagement
•Hierarchy of Controls
•Continuous Improvement
•Compliance with Regulations
•Inherent Safety
•Fail_ Save Design

5. Process Design
Consideration in Process
Safety Management
THE KEY FACTORS TO CONSIDER WHEN DESIGNING PROCESSES TO ENSURE EFFECTIVE
PROCESS SAFETY MANAGEMENT, INCLUDING HAZARD IDENTIFICATION, RISK
ASSESSMENT, AND IMPLEMENTATION OF CONTROL MEASURES.

6. Basic Principles Process Safety Management
PREVENTING CATASTROPHIC ACCIDENTS
REGULATORY COMPLIANCE
PROTECTING INVESTMENTS
CONTINUOUS IMPROVEMENT
IN SUMMARY, EFFECTIVE PROCESS SAFETY MANAGEMENT IS ESSENTIAL FOR PROTECTING WORKERS, THE
COMMUNITY, AND THE ENVIRONMENT, ENSURING REGULATORY COMPLIANCE, SAFEGUARDING INVESTMENTS,
AND DRIVING CONTINUOUS IMPROVEMENT IN INDUSTRIAL OPERATIONS.

7. The 14 Key Elements Process Safety Management
•Process Safety Information
•Process Hazard Analysis
•Operating Procedures
•Training
•Mechanical Integrity
•Management of Change
•Pre-Startup Safety Review
•Hot Work Permit
•Contractor Safety
•Emergency Planning and Response
•Incident Investigation
•Compliance Audits
•Trade Secrets
•Employee Participation

8. PERSONNEL
AND
TRAINING

9. Engineering Controls and Safeguards
PROCESS HAZARD ANALYSIS (PHA)
INHERENTLY SAFER DESIGN
PRINCIPLES
AUTOMATED SHUTDOWN AND INTERLOCK SYSTEMS
REDUNDANT EQUIPMENT AND BACKUP SYSTEMS

11. Mata Kuliah
Design dan Rekayasa K3 Magister Terapan K3
Universitas Gadjah MadaCASE STUDY #1
1
1

12. CASE STUDY
1
2
Design dan Rekayasa K3 Magister Terapan K3
Universitas Gadjah Mada
Setelah proyek Erection di salah satu project Pabrik Kimia sudah selesai dan siap untuk commisioning, salah satu plant yang
sangat penting untuk process cooling yaitu CAUSTIC ABSORTION CHILLER (CAC)
-Unit ini menghasilkan chilled water 5-10 dec C dan sekaligus menurunkan konsentrasi NaOH dari 48% menjadi 40% karena
reaksi absorbsi yang terjadi
-Untuk menjaga proses ini stabil diperlukan kondisi vacuum yang dihasilkan dari condensor, steam ejector dan small pompa
vaccum
-Chilled water ini sangat penting untuk process cooling di reactor supaya tidak terjadi over temperature yang bisa
menyebabkan ledakan pada reactor
Sebagai seorang Ahli K3 Umum / Ahli K3 Kimia / HSE Supervisor / HSE Engineer/ HSE Manager anda pasti dilibatkan sebagai Tim
PHA (Process Hazard Analysis)
1.Berikan Analisa bahaya proses PHA yang pernah anda dapatkan (HAZOP, FMEA, FTA, What If, Bow Tie Analysis )
2.Silahkan pilih salah dari metode PHA yang anda sepakati dalam group
3.Berikan Analisa anda dan buat laporan , ditabulasikan dan dilaporkan
4.Hitunglah Risk Rating / Risk Priority Number dan berikan rekomendasikan kepada Commisioning Tim sebelum dilakukan
Commisioning
Diskusikan dalam TIM PHA anda dan presentasikan

21. Design Workplaces for
Occupational Safety and
Health
Explores strategies for creating work environments that prioritize the
safety and well-being of employees, addressing key aspects of
occupational safety and health.

22. Workplace Design Considerations
•Lighting
•Workstation Ergonomics
•Noise Control
•Temperature and Ventilation
•Accessibility

23. Workplace Design Implementation
Ergonomic
Workstation Design
Machine GuardingVentilation and Air
Quality
Slip and Fall
Prevention
Proper LightingEmergency
Preparedness

24. Case Study: Ergonomic Workspace Design
Identifying the
ProblemGathering DataDesigning the
Solution
Implementing
the Changes

26. Result of Engineering Design
Redesigned factory
ventilation system
reduced exposure to
hazardous fumes by
75%
Ergonomic workstation
design lowered
musculoskeletal injury
rates by 40% in
manufacturing plant
Noise-cancelling
enclosures installation
decreased excessive
noise levels by 20 dB in
metal fabrication facility
Automated material
handling system
implementation
eliminated manual
heavy lifting,
preventing back
injuries
Machine guarding
upgrades led to zero
incidents involving
moving parts in
automotive assembly
line

27. Hazard Identification and Risk Assessment for
Workplace Design
Hazard IdentificationRisk AssessmentHierarchy of ControlsMonitoring and Review

28. Mata Kuliah
Design dan Rekayasa K3 Magister Terapan K3
Universitas Gadjah MadaCASE STUDY #2
1.Di dalam suatu ruangan produksi di perusahaan anda bertugas, terdapat 4 orang pekerja yang semuanya bekerja dengan
beban kerja TINGGI. Dalam satu hari kerja bekerja selama 8 jam sehari termasuk jumlah istirahat riil sehari dalam jam.
Dari hasil pengukuran External Laboratorium yang ditunjuk dilaporkan ISBB = 30 oC.
- Apakah tekanan panas yang memajan 4 pekerja tersebut telah melebihi NAB (Nilai Ambang Batas) ?
- Apa rekayasa Engineering yang anda usulkan untuk mengatasi tekanan Panas yang memajan 4 pekerja tersebut ?
2.Ruang Genset di perusahaan anda terletak jauh dari kantor dan ruang produksi sehingga suara tidak begitu terdengar.
Namun kebisingan di dalam ruangan genset tersebut mencapai 96 db . Operator Genset bekerja selama 8 jam sehari.
- Apakah pajanan tersebut masih di dalam NAB ? jelaskan
- Apa rekayasa Engineering yang anda usulkan untuk mengatasi hal tersebut ?
3. Pada ruang tanur tinggi untuk peleburan logam, hasil pengukuran sinar UV yang memejan operator tanur tersebut adalah = 0.4
mW/cm2. Operator bekerja 8 jam sehari.
- Apakah pajanan tersebut masih di dalam NAB ? jelaskan
- Apa rekayasa Engineering yang anda usulkan untuk mengatasi hal tersebut ?
- Apakah tindakan rekayasa tersebut effektif dan effisien ? Bagaimana anda memberikan justifikasi kepada Top manajement
bahwa itu satu satunya solusi yang harus dilakukan ? Atau anda memiliki solusi lain yang lebih effektif dan effisien ?

29. Design and
Engineering
OHS by ILO
An introduction to the topic of engineering design
for occupational health and safety, as outlined by
the International Labour Organization (ILO).

30. Introduction to Engineering Design OHS
•ILO Guidelines for Engineering Design
•Hazard Identification and Risk Assessment
•Design for Safety and Health
•Ergonomic Considerations
•Stakeholder Engagement

31. ILO's Role in Engineering Design OHS
1919
1981
1988
2001
2010

32. “Designing for safety should be
an integral part of the
engineering design process.”

33. ILO Experts in Engineering Design OHS
Jane DoeJohn SmithDr. Alice ThompsonMichael Johnson

34. Global Adoption of ILO Engineering Design OHS
ILO Safety GuidelinesGlobal Adoption MapWorker Safety ImprovementsILO Safety Certification

35. Challenges and Opportunities in
Engineering Design OHS
ChallengesOpportunities
Lack of integration of OHS considerations into the
early stages of engineering design
Developing comprehensive design guidelines and tools
to systematically integrate OHS into the engineering
design process
Limited awareness and training of engineers on OHS
principles and practices
Enhancing OHS-focused education and training
programs for engineering students and professionals

36. Collaborations and Partnerships in
Engineering Design OHS

37. The Future of ILO's Engineering Design OHS
Continuous ImprovementCollaboration with
Stakeholders
Adoption of New
Technologies
Emphasis on Sustainability

38. Key Takeaways on Engineering
Design OHS by ILO
•Importance of integrating safety into the
engineering design process
•ILO's global leadership in establishing standards and
guidelines
•Ongoing challenges and opportunities for
improvement

39. Comparing ILO's Engineering Design
OHS to Other Frameworks
ILO Engineering Design OHS92%
ISO 4500185%
OSHA Standards80%
ANSI Z1088%

40. DESIGN AND ENGINEERING FOR OHS BASED ON ISO 45001:2018

41. INTRODUCTION TO ISO 45001:2019
What is ISO 45001:2019?Scope of the StandardKey Requirements
Benefits of Implementation
ISO 45001:2019 provides a comprehensive framework for organizations to establish and
maintain a robust occupational health and safety management system, ultimately creating a
safer and healthier work environment for employees.

42. KEY REQUIREMENTS OF ISO 45001:2019
•Scope
•Normative References
•Terms and Definitions
•Context of the Organization
•Leadership and Worker Participation
•Planning
•Support
•Operation
•Performance Evaluation
•Improvement

43. BENEFITS OF IMPLEMENTING ISO 45001:2019
Improved Occupational Health
and Safety (OHS) Performance
Reduced Risks and HazardsIncreased Employee Engagement
and Morale
Enhanced Compliance and Regulatory AlignmentImproved Reputation and Competitiveness

44. HAZARD IDENTIFICATION AND RISK ASSESSMENT
Hazard IdentificationRisk AssessmentRisk PrioritizationRisk Control
Measures
Monitoring and
Review

45. HIERARCHY OF CONTROLS
Elimination
Substitution
Engineering Controls
Administrative Controls

46. CONTINUAL IMPROVEMENT IN ISO 45001:2019
1
Plan: Establish objectives and processes necessary to
deliver results in accordance with the organization's
occupational health and safety policy
2 Do: Implement the processes as planned
3
Check: Monitor and measure activities and processes with regard to the
occupational health and safety policy and objectives, and report the results
4Act: Take actions to continually improve the organization's occupational health and
safety performance

47. Implementing Effective
Occupational Safety Management Systems
(ISO 45001:2018)
Safety Policy and CommitmentRisk Management
Roles, Responsibilities, and
AccountabilityTraining and Competency
Incident Reporting and
Investigation
Monitoring, Measurement,
and Evaluation
Emergency Preparedness and
Response
Management Review and
Continuous Improvement

48. Resources