ii OCCUPATIONAL SAFETY AND HEALTH IMPROVEMENT AT CASTING PLANT
NORASIKIN BINTI HUSSIN
A project report submitted in partial fulfillment of the
requirements for the award of the degree of
Master of Engineering (Industrial Engineering)
Faculty of Mechanical Engineering
Universiti Teknologi Malaysia
APRIL 2010
iv In the name of Allah.the Beneficient,the Merciful and
To my beloved mother,father,friends….
v ACKNOWLEDGEMENT
First of all, I would like to express my sincere thanks and deepest appreciation to my
project supervisor, Assoc. Prof. Dr. Abd. Rahman bin Abdul Rahim from the Faculty of
Mechanical Engineering, Universiti Teknologi Malaysia, for his generous advices, guidance,
comments, patience, commitments and encouragement given to me in preparing and
completing this project report.
My special thanks also go to Prof. Ir. Dr. Wahyu Kuntjoro for his willingness to guide
and suggest ideas for project analysis in MSC Nastran/Patran, Ir. Haji Zulkifli Mohd Rashid,
who have given ideas in design using Solid Edge and AutoCAD system. Mr. Sahadan
Abdullah, Managing Director of DSB Casting who provides support and information about
DSB Casting.
Lastly, I would also like to extend my gratitude to all my friends, colleague’s and
those individuals who have contributed, either directly and indirectly towards the successful
compilation and completion of this project report. To my parents who always pray for my
success, I owe them forever for all they have done.
vi ABSTRACT
Occupational safety and health issues among workers are gaining prominence in
industrial sectors. To ensure that all workers are free from any hazards, preventive actions
should be given priority. These hazards can cause accidents and ill health to the workers due
to unsafe conditions or unsafe act. This project was carried out at a casting plant. The project
have identified the hazard, assess the risk and proposed control measures. Three methods are
used to collect data which are questionnaires, interviews and observations. Process with high
risk is pouring process due to manual lifting and carrying molten metal. The hot environment
cause heat stress, and sand dust can cause silicosis. Trolley was designed to eliminate the
need to carry the molten metal during pouring. Finite element analysis was carried out to
study the strength of material and suitability of the design. A ventilation system was proposed
to reduce the effect of heat stress and mineral dust from the greensand mold. Engineering
analysis was carried out during the design of the ventilation system.
vii ABSTRAK
Isu keselamatan dan kesihatan pekerja adalah sangat penting didalam sektorindustri.
Dalam memastikan bahawa setiap pekerja adalah terhindar daripada sebarang risiko bahaya
atau kemalangan, langkah-langkah pencegahan perlu diberi keutamaan. Risiko bahaya atau
kemalangan ini boleh menyebabkan kemalangan dan masalah kesihatan keatas pekerja
disebabkan akta dan persekitaran yang tidak selamat. Kajian ini dilakukan di industri
penuangandan adalah untuk mengenal pasti sebarang bahaya atau risiko yang mungkin
berlaku serta mencadangkan langkah-langkah keselamatan .Tiga kaedah digunakan dalam
pengumpulan data yang mana melalui borang kaji selidik, temuramah dan juga pemerhatian..
Risiko kemalangan yang tinggi adalah proses penuangan bahan logam, ini disebabkan cecair
logam panas masih lagi diangkat dengan menggunakan kaedah lama atau secara tradisional.
Persekitaran yang panas semasa proses penuangan juga menyebabkan tekanan haba yang
tinggi, dan udara yang berpasir, berhabuk serta berdebu boleh menyebabkan radang peparu.
Sebagai langkah pencegahan dalam mengurangkan berat yang dialami ketika menuang cecair
logam panas ke dalam acuan penuangan troli direkacipta khas untuknya. Untuk mendapatkan
ketepatan rekabentuk dan mengenal pasti tahap kesesuain troli sebagai ganti dan juga
bahannya, Kaedah Pengstrukturan Elemen diguna pakai bagi tujuan penganalisaan dan
pembuktian. Sistem Pengudaraan juga dicadangkan bagi mengurangkan kepanasan suhu dan
debu di kawasan penuangan. Sistem pengudaraan ini juga perlu dianalisa untuk mendapatkan
ketepatan pengukuran dalam mengurangkan haba panas.
viii LIST OF TABLES
TABLE NO
TITLE
PAGE
Table 2.1
Likelihood of occurrence
20
Table 2.2
Severity of hazard
21
Table 2.3
Risk matrix
21
Table 2.4
Risk level from risk matrik
22
Table 4.1
Industrial accidents at DSB Casting January 2000 until
50
October 2009
Table 4.2
Data of lost time injury (M/C)
51
Table 4.3
Data of accidents
52
Table 4.4
Background of workers
57
Table 4.5
Types of problem
58
Table 4.6
Number of injuries by job categories
59
Table 4.7
Frequency of accident
60
Table 4.8
Number of workers using PPE
62
Table 4.9
Data for injured body parts
64
Table 4.10
Temperature at pouring area
64
ix Table 4.11
Temperature at furnace
65
Table 4.12
HIRARC of pouring process
66
Table 5.1
Finite element result
74
x LIST OF FIGURE
FIGURE NO
TITLE
PAGE
Figure 1.1
Project methodology
6
Figure 1.2
Project report outline
10
Figure 3.1
HIRARC process
42
Figure 4.1
Organization chart at DSB Casting
46
Figure 4.2
Foundry layout
47
Figure 4.3
Machining and fabrication layout
47
Figure 4.4
Casting process flowchart
49
Figure 4.5
Layout of pouring area
53
Figure 4.6
Manual material handling
54
Figure 4.7
Pouring process
55
Figure 4.8
Ventilation system
55
Figure 4.9
Pouring area
56
Figure 4.10
Furnace area
56
Figure 4.11
Pareto diagram on types of problem
58
Figure 4.12
Pareto diagram for numbers of injuries by job categories
59
xi Figure 4.13
Pareto diagram of accident frequency
60
Figure 4.14
Pareto diagram number of workers using PPE
62
Figure 4.15
Layout of pouring area with ambient temperature
64
Figure 5.1
Pouring trolley design
71
Figure 5.2
Methods when using pouring trolley
71
Figure 5.3
Types of Ladle
72
Figure 5.4
Result of stress analysis of pouring trolley
73
Figure 5.5
LEV ducting design
77
Figure 5.6
LEV location
78
Figure 5.7
Location of LEV with respect to ambient temperature
79
xii LIST OF APPENDICES
APPENDIX
TITLE
PAGE
A
Questionnaire for data collection of the project
84
B
Analysis from questionnaire
90
C
Mechanical drawing of pouring trolley using solid edge
93
V19
D
Mechanical drawing of ventilation system using AutoCAD
98
2002
E
Analysis of pouring trolley using Msc Nastran/Patran
100
xiii CHAPTER 1
INTRODUCTION
1.1
Introduction
Safety and health has become major issues of every workplace. Industry, government,
the public and academia has taken significant interest and put pressure on employers about
the importance of safety and health to employees.
Both employers and employees must comply with the Occupational Safety and Health
Act 1994 and its regulations to avoid risk and accidents in workplace.
xiv Safety is vague because to some extent safety is a value judgment, but precise because
in many cases, one can readily distinguish a safe design from an unsafe one. The American
Heritage Dictionary defines safety as freedom from damage, injury or risk. The Oxford
Dictionary defines health as the state of being well, having or showing or producing or
functioning well, beneficial and good.
Many workers become seriously ill as a result of unsafe and unhealthy working
conditions. Occupational accidents are common occurrence. The number of reported
accidents has increased sharply in countries where industrial development has been rapid or
where reporting systems for accidents have improved. Accident rates remain particularly high
in hazardous industries such as manufacturing, mining, construction and forestry. There is a
growing awareness
too, of the close relationship between working conditions and
productivity. The improvement of occupational safety and health is considered an important
prerequisite for economic and social development.
In response, most governments have taken steps to review policy and legislation.
Employers and workers are becoming increasingly aware that safe and healthy working
conditions are essential for sustainable growth. It is important to realize that health and safety
problems must be solved through the commitment of all concerned. Technical solutions alone
cannot lead to concrete improvement.
The purpose of this project is to suggest improvement in safety and health at a casting
plant. The plant is a ferrous and non-ferrous foundry, and produce variety of casting products.
The company has many processes which have safety and health hazards. It is important to
implement safety and health policy and program to protect workers. This study will focus on
health and safety improvement at the casting plant.
xv 1.2
Background of the Project
Hazards at a metal foundry depend on the employees job and work station. Employees
faced different risk depending on what they did, and where they actually performed their job.
Grinders experienced more eye injuries, hot metal workers has more heat injuries, and
molders more strains, pulls and tears. Overall, injury rates adjusted for exposure were
significantly lower than expected for hot metal workers, and higher than expected for
molders. Long term employees experienced lower accident rates.
Workplace injuries may be broadly characterized as caused by either organizational or
personal factors. Organizational factors include work method, workstation layout and
exposure to hazardous noise and materials. Personal factors may include age, experience,
occupational stressors and non-work stressors. The foundry was unique in that most jobs and
workstations have different type of stressors.
Dust is one of the most common hazards likely to be found in foundries. The dust will
be in the form of fine respirable particles, and depending on the type of foundry and the
processes used, may contain significant amount of silica, lead, or other contaminant. In some
metal casting processes, respirable silicous dust is produced as a product of furnaces,
moulding sand, knockout and shakeout of casting, fettling and abrasive. Dust including
various form of silica containing materials can cause silicosis.
Manual material handling is one of health hazard in foundries and major causes of
back injury. Moulding and core making may involve the lifting, carrying and stacking of
heavy objects. A hazardous task observed in the foundry, which could contribute to low back
injuries involves pouring molten metal. Due to the high cost of automating metal pouring
operations, small and medium scale foundries still utilize the manual method for pouring.
Proper workplace design, using ergonomic principles, will prevent long-term serious injury to
xvi workers. The economical benefits are well recognised through increased production and less
downtime or lost time through absenteeism.
Lighting is important in working area that involved work that need precision,
accuracy and detail. Sufficient lighting means sufficient number of lamp in appropriate space.
Lighting can also be used to define form, shape and scale of spaces. Usually for accident to
occur there are probably some ‘near-misses’, people who work in places where accidents
frequency is high tend to work a little slower as a precaution, so there is probably some loss
of productivity. Personal injury can affect the productivity for a long period of time. For
example, in the coating process sufficient lighting is crucial to obtain a good drying surface
finished.
1.3
Research Problem
There are two areas selected for studies in this project. The first one is work
environment where the employees are exposed to dusts and extreme heat.
The second area of study is working condition which is not ergonomic. Example of
working condition not ergonomic, are glare and poor material handling causing back injury.
xvii 1.4
Methodology
The methodology in this research is shown in Figure 1.1. This project begins with
searching for a suitable manufacturing company as a case study. Understanding the company
profile, activities and manufacturing process is necessary before detail data collection is
carried out.
Literature review, include past case studies. Metal pouring process is selected for
further study. In order to understand the pouring process, visits to the company were made
regularly, followed by discussion with the supervisor, and workers to enable a better
comprehension about safety hazard and precautions during the pouring process. Information
about safety requirements and process is obtained from the company’s document.
In problem identification stage, three methods of data collection were used
observation, study of factory’s documents and interview. From here hazard identification is
carried out after analyzing collected data. Safety hazard with the highest risk are be analyzed
and recommendations are made. Recommendation and proposed improvement can reduce
risk or avoid in the pouring process.
xviii State Company
Study Company Operation
Identify Areas for Study
Literature Review
Identify hazards at selected areas
Data Collection and Analysis
Recommendation and
Proposed Solutions
Figure 1.1 Project methodology
xix 1.5
Objectives
The objectives of this project are:
i.
To identify safety and health hazard and assess risk at the casting plant.
ii.
To propose improvements.
1.6
Scope
The scopes of this research are:
i.
Focuses on safety and health improvement at sand casting process only.
ii.
Cost analysis is not included.
iii.
All suggestions must not be necessarily implemented by the company.
1.7
Definition of Terms
The definitions of the most common terms used in this project are:
a)
HIRARC means hazard identification, risk assessment and risk control.
b)
Severity is outcome from an event such as severity of injury or health of
people, or damage to property, or damage to environment, or any combination
of those caused by the event.
xx c)
Likelihood is an event likely to occur within the specific period or in specified
circumstances.
d)
Control is the elimination or inactivation of a hazard in a manner such that the
hazard does not pose risk to workers who have to enter into an area or work
on equipment in the course of scheduled work.
e)
Redesign means jobs and processes can be reworked to make them safer. For
example, containers can be made easier to hold and lift.
f)
Isolation means if a hazard cannot be eliminated or replaced, it can sometimes
be isolated, contained or otherwise kept away from workers. For example, an
insulated and air-conditioned control room can protect operators from toxic
chemical or extreme temperature.
g)
Dilution means some hazards can be diluted or dissipated. For example,
ventilation systems can dilute toxic gasses before they reach operators.
1.8
Outline of the Report
Figure 1.2 illustrates the report outline of this project. This report consists of six
chapters.
Chapter 1 describes introduction to the project and research problem. This chapter
also explains the objectives, scopes, methodology, terms and definitions used in this project.
xxi Chapter 2 explains literature review of previous work related to safety and health
hazard. These literatures discuss about theory, concept and research method.
Chapter 3, explains the methodology used in the project and background of the
company. This chapter includes the method used to collect data and identify hazards at the
company. The organization chart, company layout and process flow is also discussed in this
chapter.
Chapter 4 explains data collection and analysis. Risk assessment of sand casting
process is also carried out.
Chapter 5 discuss the proposed solutions and analysis. This chapter explained the
improvement plans proposed to the company. The results from the improvement plan were
evaluated and compared with existing condition.
Chapter 6 summarize the report and conclusion of the works. Research contribution
and recommendations for future works are explained.
xxii Introduction to Project (Chapter 1)
Literature Review (Chapter 2)
Methodology and Company Background (Chapter 3)
Data Collection and Analysis (Chapter 4)
Proposed Solution and Analysis (Chapter 5)
Conclusion and Future Work (Chapter 6)
Figure 1.2 Project report outline
1.9
Conclusion
This chapter described introduction to the project. Project background, objectives,
scopes and methodology are also discussed. The purpose of this project is to identify safety
and health hazards in casting plant, and proposed improvements to control the hazard. The
literature review is discussed in Chapter 2.
xxiii CHAPTER 2
LITERATURE REVIEW
2.1
Introduction
This chapter discuss the theory, concept and methodology of the project. Literature
review include general safety, risk assessment, sand casting process, and hazards during
casting and hazard control.
2.2
Definition
2.2.1 Accident
An accident is defined as an unplanned, unexpected occurrence that interferes with or
interrupts the orderly progress of work and potentially leads to personal injury or dollar
losses. During an accident, a person’s body comes into contact with or is exposed to some
object, other person or substance, which is injurious or the movement of a person causes
injury or creates the probability of injury (Thomas, 1989).
xxiv 2.2.2 Injury
An injury may be defined as harmful condition sustained by the body as the result of
an accident, it can take the form of an abrasion, a bruise, a laceration, a fracture, a foreign
object in the body, a punctured wound, a burn or an electric shock.(Thomas,1989).
2.2.3 Unsafe Act
An unsafe act is a violation of an acceptable safe procedure, which could permit the
occurrence of an accident. Some unsafe acts are so hazardous that it takes very little action
before the occurrence of an accident (Thomas, 1989).
2.2.4 Unsafe Condition
An unsafe condition is a hazardous physical condition or circumstances that could
directly permit the occurrence of an accident. This could be the result of an unsafe act by
someone (Thomas, 1989).
2.2.5 Danger
The definition of "danger" includes any existing or potential hazard or condition and
any current or future activities. The notion of immediacy has been clarified by specifying that
the injury or illness need not follow immediately. Hazard is also clarified by adding the
wording "existing and potential" to hazard (OHSAS 18000: 1999).
xxv 2.2.6 Hazard
Hazard is a sources or situation with a potential for harm in terms of injury or ill
health, damage to the workplace environment or a combination of these. (OHSAS 18000:
1999)
2.2.7 Hazard Control
The process of implementing measures to reduce the risk associated with a hazard.
(OHSAS 18000: 1999)
2.2.8 Risk
Risk means a combination of the likelihood of an occurrence of a hazardous event
with specified period or in specified circumstances and the severity of injury or damage to the
health of people, property, environment or any combination of these caused by the event.
(OHSAS 18000: 1999)
2.3
Occupational Safety and Health Act 1994 (OSHA)
The Occupational Safety and Health Act 1994 provides a legislative framework to
stimulate and encourage high standards of safety and health at work and also promote safety
and health awareness and establish effective safety organization through self-regulation. It
consists of 15 parts and is an enabling measure superimposed over existing safety and health
regulations.
xxvi OSHA provisions prevail in the event of any conflict. Unlike the Factory and
Machinery Acts 1967 (FMA), OSHA does not go into great detail regarding specific
requirements instead it provides statutory guidelines on the duties of employers, employees,
manufacturers and suppliers. It provides also for the implementation of industry codes of
practice and the making of regulations. OSHA also sets out the framework of policy making
body such as National Council for Occupational Safety and Health. A very important aspect
of OSHA that departed from the earlier style of legislation is the application of the Act to
“persons at work”. This means that many more people who were previously not covered are
now embraced by the provision of the Act.
2.3.1 Objectives of OSHA 1994
Objective of OSHA 1994 are
i.
To secure the safety, health and welfare of persons against risks from work
activity
ii.
To promote an environment which is adapted to physiological and
psychological needs
iii.
To provide the means to progressively replace legislation by a system of
regulations and approved industry codes of practice.
2.3.2 Scopes
The Act also clearly defines the terms like “employee”, workplace” and “industry” to
avoid misinterpretation or confusion among the users. With these clear definitions, the
enforcement of the Act becomes more systematic and easy.
“Employee” is defined as a person who is employed for wages under a contract of
service or in connection with the work of an industry either permanent or temporary.
xxvii Where else, “workplace” is defined as premises where person works or premises used for
storage of plants substances. Meanwhile “industry” is defined as the public services, statutory
authorities or any of the economic activities. Industries that are covered under OSHA 1994
are:
2.4
i.
Manufacturing
ii.
Mining and quarrying
iii.
Construction
iv.
Agriculture, forestry and fishing
v.
Utilities including electricity, gas, water, sanitary services
vi.
Transport, storage and communication
vii.
Wholesale and retail trade
viii.
Hotel and restaurants
ix.
Finance, insurance, real estate and business services
x.
Public services and statutory authorities
Hazard Identification, Risk Assessment, and Risk Control (HIRARC)
The purpose of HIRARC is to provide a systematic and objective approach to
assessing hazards and their associated risks that will provide an objective measure of an
identified hazard as well as provide a method to control the risk. It is one of the general duties
as prescribed under the Occupational Safety and Health Act 1994 (Act 514) for the employer
to provide a safe workplaces to their employees and other related persons
2.5
Hazard Identification
Hazard identification means the identification of undesired events that lead to the
materialisation of the hazard and the mechanism by which those undesired events could
occur. The purpose of hazard identification is to highlight the critical operations of tasks, that
xxviii is, those tasks posing significant risks to the health and safety of employees as well as
highlighting those hazards pertaining to certain equipment due to energy sources, working
conditions or activities performed. Hazards can be divided into three main groups, health
hazards, safety hazards, and environmental hazards.
2.5.1 Health Hazard
An occupational health hazard is any agent that can cause illness to an individual. A
health hazard may produce serious and immediate (acute) affects, or may cause long-term
(chronic) problems. All or part of the body may be affected. Someone with an occupational
illness may not recognize the symptoms immediately. For example, noise-induced hearing
loss is often difficult for the affected individual to detect until it is well advanced. Hazards
include chemicals (such as battery acid and solvents), biological hazards (such as bacteria,
viruses, dusts and molds), physical agents (energy sources strong enough to harm the body,
such as electric currents, heat, light, vibration, noise and radiation) and work design
(ergonomic) hazards.
2.5.2 Safety Hazard
A safety hazard is any force strong enough to cause injury, or damage to property. An
injury caused by a safety hazard is usually obvious. For example, a worker may be badly cut.
Safety hazards cause harm when workplace controls are not adequate. Some examples of
safety hazards include, but are not limited to –
i.
slipping/tripping hazards (such as wires run across floors);
ii.
fire hazards (from flammable materials);
iii.
moving parts of machinery, tools and equipment (such as pinch and nip points);
iv.
work at height (such as work done on scaffolds);
v.
ejection of material (such as from molding);
xxix vi.
pressure systems (such as steam boilers and pipes);
vii.
vehicles (such as forklifts and trucks);
viii.
lifting and other manual handling operations; and working alone.
2.5.3 Environmental Hazard
An environmental hazard is a release to the environment that may cause harm or
deleterious effects. An environmental release may not be obvious. For example, a worker
who drains a glycol system and releases the liquid to a storm sewer may not be aware, of the
effect on the environment. Environmental hazards cause harm when controls and work
procedures are not followed.
2.5.4 Hazard Identification Technique
The employer shall develop a hazard identification and assessment methodology taking into
account the following documents and information –
a) any hazardous occurrence investigation reports;
b) first aid records and minor injury records;
c) work place health protection programs;
d) any results of work place inspections;
e) any employee complaints and comments;
f) any government or employer reports, studies and tests concerning the health and
safety of employees;
g) any reports made under the regulation of Occupational Safety and Health Act,1994
h) the record of hazardous substances; and any other relevant information.
2.6
Analyze and Estimate.Risk
xxx Risk is the determination of likelihood and severity of the credible accident/event
sequences in order to determine magnitude and to prioritize identified hazards. It can be done
by qualitative, quantitative or semi quantitative method.
A qualitative analysis uses words to describe the magnitude of potential severity and
the likelihood that those severity will occur. These scales can be adapted or adjusted to suit
the circumstances and different descriptions may be used for different risks. This method uses
expert knowledge and experience to determine likelihood and severity category.
In semi-quantitative analysis, qualitative scales such as those described above are
given values. The objective is to produce a more expanded ranking scale than is usually
achieved in qualitative analysis.
Quantitative analysis uses numerical values (rather than descriptive scales used in
qualitative and semi-quantitative analysis) for both severity and likelihood using data from a
variety of sources such as past accident and from scientific research. Severity may be
determined by modelling the outcomes of an event or set of events, or by extrapolation from
experimental studies or past data. Severity may be expressed in terms of monetary, technical
or human impact criteria, or any of the other criteria. The way in which severity and
likelihood are expressed and the ways in which they are combined to provide a level of risk
will vary according to the type of risk and the purpose for which the risk assessment output is
to be used.
2.6.1 Likelihood of an Occurrence
This value is based on the likelihood of an event occurring. Assessing likelihood is
based on worker experience, analysis or measurement. Likelihood levels range from “most
likely” to “inconceivable.” For example, a small spill of bleach from a container when filling
xxxi a spray bottle is most likely to occur during every shift. Alternatively, a leak of diesel fuel
from a secure holding tank may be less probable.
Table 2.0 shows likelihood and ratings.
Table 2.0 Likelihood of an occurrence
LIKELIHOOD (L)
EXAMPLE
RATING
Most likely
The most likely result of the
5
hazard/event being realized
possible
Has a good chance of occurring and is
4
not unusual
conceivable
Might occur at sometime in the future
3
Remote
Has not been known to occur after
2
many years
Inconceivable
Is practically impossible and has never
1
occured
2.6.2 Severity of Hazard
Severity can be divided into five categories. Severity is based upon an increasing level of
severity to an individual’s health, the environment, or to property. Table 2.1 shows severity
of hazards.
Table 2.1 Severity of hazard
SEVERITY(S)
EXAMPLE
RATING
Catastrophic
Numerous fatalities,irrecoverable
5
property damage and productivity
Fatal
Approximately one single fatality or
major property damage if hazard is
4
xxxii realized
Serious
Non-fatal injury,permanent disability
3
Minor
Disabling but not permanent injury
2
Negligible
Minor abrasions,bruises,cuts,first aid
1
type injury
2.6.3 Risk Assessment
Risk assessment is an overall process of estimation the magnitude of risk and deciding
whether or not the risk is tolerable. Risk can be presented in variety of ways to communicate
the results of analysis to make decision on risk control. For risk analysis that uses likelihood
and severity in qualitative method, presenting result in a risk matrix is a very effective way of
communicating the distribution of the risk throughout a plant and area in a workplace as
shown in Table 2.2.
Risk can be calculated using the following formula:
L x S = Relative Risk
L = Likelihood
S = Severity
Table 2.2 Risk matrix
xxxiii To use this matrix, first find the severity column that best describes the outcome of
risk. Then follow the likelihood row to find the description that best suits the likelihood that
the severity will occur. The risk level is given in the box where the row and column meet.
The relative risk value can be used to prioritize necessary actions to effectively manage work
place hazards. Table 2.3 determines priority based on the following ranges:
Table 2.3 Risk level from risk matrix
2.7
Sand Casting Process
xxxiv Figure 2.0. Outline of production steps in a typical sand casting operation
Figure 2.0 shows outline of production steps in a typical sand casting operation. The
main generic processes in foundries are listed below;
a. Pattern/tool making
b. Mould preparation
c. Metal preparation
d. Metal melting
e. Casting
f. Removal of castings
g. Fettling and finishing
h. Heat treatment
i. Material handling and packaging.
Most founding establishments will involve all or some of the above and many of these
processes will involve significant hazards which will require effective management. What
follows is a brief description of each process, a general statement about the process, and a list
of possible hazards.
2.7.1 Pattern/Making
Pattern making is the process of manufacturing the tooling for producing the final
component from the metal casting process. Pattern making involves a number of processes
which may be hazardous. Woodworking machinery, wood dust, noise, and chemicals are all
found in pattern making workshops. The use of epoxy resins and related chemicals is a
particular hazard. Potential hazards include woodworking machinery, metalworking
machinery, noise, dust, chemical solvents, hand tools, material and manual handling fumes.
xxxv 2.7.2 Mould Preparation
This is a process by which a mould is formed, by manual or mechanical means. It is a
vessel which is the reverse image of the final component into which the molten metal is
poured. Moulds and cores are usually made of quartzose sand bonded with clay or other
materials such as silicates, resins and isocyanates. The moulding sand is packed around the
pattern within a moulding box to form a mould section. The complete mould may consist of
an assembly of two or more sections or parts. Potential hazards in mold preparation are
moulding machines, dust, noise or vibration, chemical solvents, fumes, manual handling, heat
and flames.
2.7.3 Metal Preparation
This is the process of segregation and preparation of alloys and scrap prior to the
melting process. Metal is prepared and weighed ready for the furnace. Depending on the type
of foundry, the metal will include pig iron, metal ingots, and scrap. Sorting out undesirable or
unsatisfactory metal will be an important process. Metal containing contaminants such as
lead based paint should be excluded as well as items such as porcelain baths. For safety
reasons metal being added to a hot furnace must be dry. Potential hazards are sharp edges, hot
material, dust, sparks, material manual handling, toxic waste and heavy metal contamination.
2.7.4 Metal Melting
This is the process by which metals are melted to a controlled temperature and
composition. Metal, which may be steel, stainless steel, iron, aluminium, bronze, brass and
various alloys, may be melted by: electric arc, resistance or induction. a cupola furnace using
coke; or oil or gas burning furnaces. Molten metal may then be metallurgically processed
xxxvi before being transferred to the mould by ladle or other means. Potential hazards in melting
are moisture, fumes, explosions, equipment failure and material manual handling.
2.7.5 Casting
This is the process of transferring the molten metal into the prepared mould for
solidification. The molten metal is poured into moulds by any one of a number of methods
depending on the process used but will usually involve a refractory lined steel. When molten
metal is poured into sand moulds the sand is subjected to a high temperature (about 1600ºC in
the case of steel). This temperature is sufficient to convert some of the quartz in the sand of
the mould to cristobalite which is a significant respiratory hazard. Potential hazards are
molten metal, latent heat, fumes, dusts, material manual handling, equipment failure,
moisture and explosions.
2.7.6 Removal of Castings
This is the process of removing the casting from the moulding medium in preparation
for fettling and finishing. The process of removing the casting from the mould, is known as
knockout or shakeout. The cool casting is removed by knocking it away from the mould by
hand or using vibrators or pneumatic tools. Significant noise and dust hazards are created by
these processes. Runners, risers and parts of the casting not forming part of the finished
article, are removed by knocking or sawing from the casting, which is then ground on a
grinding wheel to remove flashes, rough edges and runner remnants. Castings are usually
dressed by fettling or abrasive blasting but small items may be rumbled in rotating drums.
Potential hazards are noise, dusts, fumes, heat, sharp edges, manual material handling and
waste.
2.7.7 Fettling and Finishing
xxxvii This is the process of removing excess material from the casting to meet specified
dimensions. Fettling and finishing involves a number of different processes depending on the
type of foundry. This is an area in which many different types of hazards are found making it
an important place to implement proper controls.
Potential hazards are noise or vibration, dusts, thermal cutting, fumes, sharp edges,
grinding and cutting machine, abrasive cleaning, and mechanical manual handling.
2.7.8 Heat Treatment
This is the process of enhancing the metallic structure and physical properties of the
component by the use of controlled temperatures. Heat treatment will be used in specialize
applications and because it involves heat, the danger from burns and other effects of heat
need to be guarded against. Potential hazards are radiant heat, steam, mechanical or manual
handling, chemicals, fire, explosions, dust, waste, fume and equipment failure.
2.7.9 Material Handling and Packaging
This is the process of handling materials throughout the casting process and the
presentation of components for dispatch to meet customer specifications. Potential hazards
are manual material handling, sharp edges, lack of traceability and incorrect storage and
stacking.
2.8
Accident in Foundries
xxxviii Injuries experienced at a metal foundry depended on the employee’s job category,
workstation, and length of employment. Employees faced different levels of risk depending
on what they did, and where they actually performed their job.
The Bureau of Labor Statistics USA estimated a 1992 injury rate for the iron and steel
industry of 27.7 nonfatal injuries and illnesses per 100 full-time workers (National Safety
Council USA, 1994), compared to a rate of 12.5 for general manufacturing jobs. The foundry
recorded 846 accidents between 1980 and 1995, or 75.5 per 100 workers per year. This
accident caused 2,251 lost work-days due to injuries, or 2001 per 100 workers. The nominal
accident rate was high compared to the 27.7 per 100 workers reported for the iron and steel
industry overall in 1992, but this was largely due to high number of mild eye injuries (foreign
particles in eyes) recorded for grinders (Terry Dell and Berkhout year).
The highest number of injuries involved foreign particles in eyes (40%), strains, pulls
and tears (31%), bruises (11%), cuts and puncture wounds (9%), burns and scalds (5%), and
broken bones (4%). Particle injuries were obviously more important than any of the other
physical injuries recorded in the foundries.
2.9
Types of Dust
Dust is one of the most common hazards likely to be found in foundries. The dust can
be in the form of fine respirable particles, and depending on the type of foundry and the
processes used, may contain significant amount of silica, lead, or other contaminants.
i) Respirable Siliceous Dust
In some metal casting processes respirable siliceous dust is produced as a product of
furnaces, moulding sand, knockout and shakeout of castings, fettling and abrasive blasting.
xxxix ii) Furnaces
Repeated heating converts the quartz of the firebricks and silica refractory lining
furnaces to amorphous silicates of cristobalite and tridymite. Workers maintaining and
replacing the refractory material may be exposed to dust containing significant amounts of
cristobalite which is highly fibrogenic (causing the disease silicosis if inhaled into the lung).
In the past grouting material used to retain the firebricks often contained asbestos but this has
now been superseded. A high degree of respiratory protection therefore will usually be
required for workers during this process .
iii) Moulding
Heat from the molten metal in a sand mould produces two reactions. It reduces the
sand-containing quartz in the mould to dangerously fine respirable particles and, it converts
some into hazardous silicates, such as cristobalite. These forms of silica can cause the lung
disease silicosis. This risk varies according to the efficiency of dust control, whether the sand
is screened or not, and whether the mould is wet or dry.
Some "parting powders", contain a high content of fine silica dust, and should not be used if
possible. The use of compressed air to clean dust from moulds is likely to produce airborne
respirable dust and should be avoided.
iv) Sand Handling
Sand will be handled in a variety of ways in the metal casting process, ranging from
manual, pneumatic, or conveyors. Each method will produce significant amount of dust some
of which contain airborne silica. Appropriate measures must be taken to control dust
emissions, or the wearing of personal protection, whenever this occurs.
v) Knockout/Shakeout of Castings
xl During the knockout process there are a wide variety of dusts produced of which
alumino silicates and alumina are the most common .These processes also liberate fine silica
dust into the air and the environment of the foundry. If this dust is inhaled there is a risk of
silicosis. Because fine dust is raised from the floor as airborne particles by draughts, people
walking over the floor, and movement of vehicles such as forklifts, total dust control is an
important item in plant housekeeping and hazard management.
vi) Pattern Shop
The increased use of particle board in pattern making causes increased levels of wood dust
and formaldehyde binders which are both recognised health hazards.
vii) Core Making
There are a variety of mineral sands used in core making. These can include zircon,
chromate, magnesite and alumina silicates. In keeping with good work practices exposure to
these dusts should be avoided by the use of appropriate control measures.
viii) Metal Melting
In this process, dust is generated, which will contain a wide variety of chemicals.
These will be carried into the ventilation system where this is installed. If ventilation
extraction is not installed, appropriate protective measures must be taken for workers in the
area.
xli 2.10
Noise
Excessive noise is a common hazard in foundries and causes permanent occupational
deafness to those exposed. Sources of noise include:
i.
Metal impacting upon metal (shakeout, core, knockout tumbling, chipping,
handling and transport of castings);
ii.
Exhaust from compressed air operated machines and tools (moulding
machines, chipping hammers, grinders, hoists);
2.11
iii.
Electric furnaces, ladle heaters;
iv.
Conveyors;
v.
Wood saws and other machinery in the pattern shop;
vi.
Electric arc cutting;
vii.
Core blowers, sand slingers and high pressure moulding machines
viii.
Shot blasting.
Vibration
Grinders, pneumatic chipping hammers, chisels and electrically operated rotary
grinders can produce "dead hand" or vibration white finger if used extensively. Where people
are exposed to whole or part body vibration the exposure must be controlled within limits that
protect them from adverse health effects.
The condition usually affects both hands, with the index, ring and middle fingers suffering
the most.
2.12
Manual Handling
xlii Manual material handling is one of the major causes of severe industrial injury
especially for back injury. Previous study about the effects of different mold heights and
carrying distances on physiological responses and determine maximum acceptable task
frequencies (MAF) for metal pouring. Many of these injuries arise from improper handling of
materials. The direct and indirect costs are enormous, and the human suffering associated
with low back injuries is immeasurable (Kroemer et al., 2001). In order to control the
frequency, severity and tremendous economic losses of these injuries, a variety of research
and design guidelines have been proposed (Davis and Stubbs, 1980: Waters et al., 1993;
National Occupational Health and Safety Commission, 1995).
In the 2004 annual report, Liberty Mutual Research Center for Safety published The
Liberty Mutual Workplace Safety Index, which revealed that overexertion, comprising of
injuries due to lifting, pulling, holding, carrying or throwing of an object, was the number one
cause for workplace injuries in 2002 and ranked among the top five during the preceding
years ( Fredericks,)
Furthermore, back injuries result in much more lost job time (Chaffin,1987). The total
cost of back injuries in the USA in 1991 was reported to be between 50 and 100 billion
dollars (National Institute for Occupational Safety and Health,1997). A hazardous task
observed in the foundry, which could contribute to low back injuries involves pouring molten
metal. However, due to the high cost of automating metal pouring operations, many small
scale foundries still utilize the manual method for pouring metal. Karim et al. (1998)
conducted a study in a foundry to document energy expenditure while pouring metal at
different combinations of mold heights and carrying distance.
2.13
Potential health risk in foundries
The potential health risk in foundries are listed below;
i.
Occupational overuse syndrome (OOS)
xliii ii.
Cancer
iii.
Dermatitis
iv.
Stress
v.
Fatigue
vi.
Metal fume fever
vii.
Vibration white finger
viii.
Burns
ix.
Soft tissue injuries
x.
Lead poisoning
xi.
Respiratory disease
xii.
Sprains and strains
xiii.
Back injuries
xiv.
Eye injuries
xv.
Silicosis
xvi.
Noise-induced hearing loss
2.14
Methods to Control Workplace Hazards
All workplace hazards (chemical, physical, etc.) can be controlled by variety of
methods. The goal of controlling hazards is to prevent workers from being exposed to
occupational hazards. Some methods of hazard control are more efficient than others, but a
combination of methods usually provides a safer workplace than relying on only one method.
Some methods of control are cheaper than others but may not provide the most effective way
to reduce exposures.
The most effective method of controlling hazards is to control at the source by
eliminating the hazard or by substituting a hazardous agent or work process with a less
dangerous one. Some methods to control workplace hazards such as :
xliv i) Elimination
Elimination of a specific hazard or hazardous work process, or preventing it from entering the
workplace, is the most effective method of control.
ii) Substitution
If a particularly dangerous chemical or work process cannot be completely eliminated, then
replace it with a safer substitute.
iii) Engineering Controls
There are a number of common control measures which are called “engineering controls”.
These include enclosure, isolation and ventilation.
a) Enclosure
If a hazardous substance or work process cannot be eliminated or substituted, then
enclosing it so workers are not exposed to the hazard is the next best method of control.
Many hazards can be controlled by partially or totally enclosing the work process. Highly
toxic materials that can be released into the air should be totally enclosed, usually by using a
mechanical handling device or a closed glove system that can be operated from the outside.
xlv b) Isolation
Isolation can be an effective method of control if a hazardous job can be moved to a
part of the workplace where fewer people will be exposed, or if a job can be changed to a
shift when fewer people are exposed (such as a weekend or midnight shift). The worker can
also be isolated from a hazardous job, for example by working in an air-conditioned control
booth.
c) Ventilation
Ventilation in the workplace can be used for two reasons: (1) to prevent the work
environment from being too hot, cold, dry or humid; (2) to prevent contaminants in the air
from getting into the area where workers breathe. Generally there are two categories of
ventilation: local exhaust ventilation and general ventilation. Whatever the type, ventilation
should be used together with other methods of control.
iv) Administrative Controls
Administrative controls limiting the amount of time workers spend at a hazardous job
can be used together with other methods of control to reduce exposure to hazards. Some
examples of administrative controls include:
a. Changing work schedules (for example, two people may be able to work for four
hours each at a job instead of one person working for eight hours at that job).
b. Giving workers longer rest periods or shorter work shifts to reduce exposure time.
c. Moving a hazardous work process to an area where fewer people will be exposed.
d. Changing a work process to a shift when fewer people are working.
xlvi v) Personal Protective Equipment
Personal protective equipment (PPE) is the least effective method of controlling
occupational hazards and should be used only when other methods cannot control hazards
sufficiently. PPE can be uncomfortable, can decrease work performance and can create new
health and safety hazards. The appropriate use of personal protective equipment (PPE) can
reduce injuries and illness (Breish, 1989; LaBar, 1990). According to OSHA statistics, about
12 – 14% of total disabling occupational injuries occurs because workers do not wear
appropriate PPE (Breish, 1989).
Several types of PPE are recommended or required at the plant
a) Side-shield safety glasses are required on the factory floor.
b) Safety goggles are worn when cleaning the mould in the moulding department.
c) Face-shields are worn while servicing lift-truck batteries or handling water treatment
corrosive liquids
d) Leather shoes that cover the entire foot are required on the factory floor.
e) Boot covers are recommended for painters and the workers who prime raw glass.
f) Chemical-resistant gloves are worn when the workers are handling solvents and
primers.
g) Cut-resistant gloves are worn on the worker’s non dominant hand if a razor blade or
utility knife is being used.
h) Half-mask respirators with organic vapour cartridges are required when spraying the
in-mould urethane coating.
i) Hearing protection is mandatory in moulding and painting areas.
j) Disposable coveralls are required when spray painting in the paint booth.
k) Embossed polyurethane aprons are recommended when priming raw glass.
l) Disposable sleeves are recommended for workers priming glass or spraying urethane
paints in the moulding department.
m) Sleeves also are available for workers using razor blades.
n) Employees who have to lean against the metal frame of the clamp in the moulding
department are advised to wear knee and elbow pads.
xlvii 2.15
Conclusion
This chapter is describes literature reviews related to safety and health hazard in foundry. The
objective of this review is to understand safety hazard and control in foundry.
xlviii CHAPTER 3
METHODOLOGY
3.1
Introduction
This chapter discuss on the methodology to collect and analyze data to identify
hazards and proposed control measures. The study focus on safety and health hazards in the
casting area.
3.2
Justification for the Methodology
In identifying the safety and health hazards, a few methods are used. The methods
are:
i.
Questionnaire survey of the workers
ii.
Interviews with the workers and management
iii.
Observation and discussion
iv.
Information from the company
xlix 3.2.1
Survey of Workers
A survey was conducted by distributing questionnaire to casting plant workers. The
responses from the workers are essential in determining the problem. The result of the survey
can identify hazard and risk.
The questionnaires were distributed to the workers. The workers are allowed to
choose more than one answer if necessary. Additional comments from the workers can be
stated in the columns provided. A sample of the survey question is shown in Appendix A.
3.2.2
Interviews
An interview with workers and administrative staffs of casting plant was carried out.
Questions related to safety and health hazards at workplace are asked. The feedbacks are
important to obtain first-hand information in hazard identification and risk assessment.
3.2.3
Observation and Discussion
Observation is conducted on the pouring process during working hours. Information
on current work procedure and safety precautions that were used were obtained. Workers
sometimes do not follow standard work procedure because of inconvenience.
l Nevertheless, observation alone cannot gain much information. Discussion was
made with the officer, supervisor and workers in order to get a better view of work
procedures and safety precautions in the pouring process. Three different group of people
were chosen for discussion to obtain information regarding safety problems in pouring
process. The discussion was mainly about their opinion towards safety in the company.
3.2.4
Information from Company
Information from the company is important to support information gathered by
observation. The company did not have accident record. Information on safety precautions
and work procedures is also important.
3.3
Research Procedures
3.3.1 Data Analysis
The primary method used for data analysis is the survey. Questionnaires were
distributed to 33 workers, (30 male and 3 female) at casting plant. The questionnaires listed
questions on hazards in the casting plant. The workers are exposed to various hazards at any
workstation in the casting plant and they can identify safety hazards.
li In this study, the questionnaire was divided in to 6 areas, background of workers,
types of accidents, health problem, personal protective equipment, manual handling and heat
stress. The main objective is to get information on safety and health hazard among workers at
casting plant. Charts will be used to analyze the questionnaire. Once safety and health hazard
has been identified, brainstorming and discussion will be held to determine possible solutions
to improve safety and health condition at casting plant.
The secondary method used for data analysis is by referring to guidelines for hazard
identification, risk assessment and risk control (HIRARC). The purpose of this guideline is to
provide a systematic and objective approach to assessing hazards and their associated risks to
provide an objective measure of identified hazards as well as to provide methods to control
risk.
3.3.2 Planning and Conducting HIRARC
The purpose of HIRARC is to identify all factors that can cause harm to employees.
Figure 3.1 shows the flowchart of HIRARC process.
lii Classify work
activities
Review
Consultation
Review
Identify hazards
Review
Risk assessment
Prepare risk control
action plan
(if necessary)
Implement
Figure 3.1 HIRARC process
HIRARC process requires four simple steps;
a)
Classify work activities
b)
Identify hazard
liii c)
Conduct risk assessment (analyze and estimate risk from each hazard), by calculating
or estimating:
d)
i.
Likelihood of occurrence
ii.
Severity of hazard
Decide if risk is tolerable and apply control measures (if necessary).
3.3.3 Risk Analysis
This objective is to identify safety and health hazard during pouring process at
pouring workstation and to determine risk control. The steps to conduct risk analysis are;
a)
Choose the work station to conduct risk analysis. The pouring workstation at casting
plant is selected.
b)
Prepare a list of potential hazard for the workstation to be studied. Table 2.1 and
Table 2.2 shows the severity of hazard and likelihood of occurrences.
c)
Prepare a risk analysis work sheet to record potential hazards.
d)
Carry out analysis.
3.4
Conclusion
This chapter has explained the methodology applied in the project and the sequence to
carry out the analysis. The casting plant does not have a proper safety management system. It
is important to improve the company's safety condition to prevent accidents.
liv CHAPTER 4
DATA COLLECTION AND ANALYSIS
4.1
Introduction
This chapter discuss data collection and data analysis at casting plant. Data will be
analyzed in tables and chart to ease the understanding. After data analysis, safety hazards can
be identified and suggestion for improvement can be made.
4.2
Data Collection
Data in this project is obtained from questionnaires that been given to the workers and
interview with management. Some information is gathered by observation. Background of
casting plant where this case study was carried out is explained.
lv 4.2.1 Case Study Background
4.2.1.1 Casting plant
Casting plant is a ferrous and non-ferrous foundry and started its operation in January
1994. The building is located on 40,000 square feet land in Bandar Darulaman Industrial
Estate, Kedah.
Casting plant is involved in casting of products such as agriculture machinery parts,
manhole cover, waterworks/valve, heavy machinenery parts and replacement parts for
industrial used. In 1999 casting plant has diversified its operations to include fabrication
works, general engineering and machining.
4.2.1.2 Casting plant Organization
Figure 4.1 shows the organization chart of casting plant. The company has two main
departments, administration and production department. Production at casting plant has two
sections; factory and foundry. Each department is managed by one manager. Each manager
reports to the managing director. This project will focus on foundry section. The foundry
section has 33 personnel, 30 male and 3 female staffs.
lvi Managing Director
Director
Administration
Sales &
Purchasing
Dept
Production
Account
Dept
HR Dept
Factory Manager
Foundry Manager
Machining &
Fabrication Sectioning
Foundry Section
Figure 4.1 Organization chart at casting plant
4.2.1.3 Casting Plant Plant Layout
The total land area of this company is 40,000 square feet. The foundry area 25,150
square feet and the rest is fabrication area. The foundry area has three major departments;
moulding, pouring and shakeout.
lvii Figure 4.2 Foundry layout
Figure 4.3 Machining and fabrication layout
lviii 4.2.1.4 Process Flow Chart of Casting Plant
Figure 4.4 shows the process flowchart for casting at casting plant. In casting plant
has three main activities; pattern making, prepare mold and core and pouring process. In the
sand casting process, pattern is made in the shape of the desired part. The pattern is typically
made of wood, plastic, or metal. Basically, sand casting operations use silica sand (SiO²) as
mold material and making core. In sand mixing machine, sand is mixed together with natrium
silicate for mould making and core. CO2 are using to harden the mold and core. Next, the
mold must be coated and dried before pouring molten metal into mold. Coating is to avoid air
and moisture trapped in the mold.
Molten material is poured in the pouring cup, which is part of the gating system that
supplies molten material to the mold cavity. After solidification, the casting is shaken out of
its mold, and the sand and oxide layers adhering to the casting are removed by sand blasting.
Casting product is cleaned by blasting with steel short. The casting subsequently may be heat
treated to improve certain properties required for its intended service use; these processes are
important, particularly for steel castings. Finishing operations may involve machining and
grinding to obtain final dimensions. Inspection is an important final step and is carried out to
ensure that the casting meets all design and quality control requirements.
lix Figure 4.4 Casting process flowcharts
4.2.2
Casting Plant Safety Report
Casting plant safety report shows accident record from January 2000 until October
2009, data of medical certificate and accident data in 2009.
lx 4.2.2.1 Accident Reports from January 2000 until October 2009
Accidents at workplace can happen if the procedures or rules are not followed.
Statistics of accident starting from January 2000 until October 2009 shows that the number of
accidents at casting plant decreased every year. Total numbers of accidents in 2000, 2004 and
2007 are high compared to other years. Table 4.1 shows the statistic of accidents at casting
plant from January 2000 until October 2009.
The company should take necessary actions to reduce the accidents rate and also to ensure
safety at workplace. The results from the analysis done at the factory, several factors that
contribute to accident are machine, splashed molten metal and unsafe work method:
Table 4.1 Industrial accidents from January 2000 until October 2009
NO. OF CASES/ ACCIDENTS
MONTH
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
January
1
0
0
1
0
0
1
0
0
1
February
0
0
1
2
1
0
0
1
0
0
March
2
0
0
1
0
1
2
0
1
0
April
1
0
1
0
1
0
1
1
0
2
May
0
1
1
0
1
0
0
1
0
0
June
0
0
2
0
2
0
1
2
0
0
July
2
0
1
0
1
0
0
1
0
1
August
0
1
1
0
1
0
0
1
2
0
September
0
1
1
0
1
0
0
1
1
1
October
1
0
0
1
3
1
0
2
1
November
1
0
0
0
0
1
0
1
1
December
2
0
0
0
0
1
0
1
0
TOTAL
10
3
8
5
11
4
5
12
6
5
lxi 4.2.2.2 Total Lost Time Injury
Table 4.2 show the data of loss time injury based on medical certificate of workers.
Year 2000 and 2007 shows increasing trend with 15 days medical certificate. From year 2001
until 2006 (except 2004) data shows that medical certificate was less than 10 days. The
medical certificate was given to workers when they got injured during working days.
TOTAL
(DAYS)
2000
15
Table 4.2 Data of lost time injury (M/C)
YEAR (JAN – DEC)
2001 2002 2003 2004 2005 2006 2007
4
10
5
11
4
8
15
2008
6
4.2.2.3 Data of Accidents in 2009
Table 4.3 shows data of accidents at for 2009. Table 4.1, shows one case in at January
and Table 4.3 described the type of accident. On 21st January, worker 2 was injured because
flying splinter to hit his face whiles making pattern of mold. There were two cases in April
involving worker 27 and worker 15. Worker 27 was working at the pouring process, but his
foot was injured when his nail was crushed. Workers 15 got injured when flying particles hit
his stomach and hand. In September, Worker 33 was working at shakeout injured his right
hand thumb when he wanted to lift the casting product.
lxii DATE
WORKER
21-Jan
Worker 2
6-Apr
Worker 27
23-Apr
Worker 15
3-Sep
Worker 33
Table 4.3 Data of accidents
M/C
JOB
INJURED
MACHINED
(DAYS)
PART
INVOLVED
1
Pattern
Face injured
Cutting saw
Maker
(flying wood
splinter)
2
Pouring
R/L foot
No machine
(nail crushed)
involved
1
Pouring
Flying
No machine
particles on
involved
stomach and
hand
1
Shakeout
R/H thumb
No machine
( nail portion
involved
crushed)
4.2.3 Indoor Air Quality (IAQ) Monitor
Indoor air quality equipment, are used for monitoring indoor air environment such as
temperature, humidity, gases including carbon dioxide, ammonia, carbon monoxide, and
chlorine. IAQ monitor are used at buildings that are served by a common ventilation and/or
air conditioning system.
Figure 4.5 shows the layout of the pouring area. The IAQ measurement data was
taken based on the layout. The pouring area are divided into two sections; pouring process
with 64 points and furnace with 24 points. The data for one location at pouring process was
taken three times in two minutes duration and distance point to point is 5 feet (y-axis) and 4.5
feet (x-axis). The data for one location at the furnace was taken three times in two minutes
duration and distance point to point is 3.5 feet (y-axis) and 4feet (x-axis). The indicator for
each point in Figure 4.5; for example A#8 means pouring process location A at point 8 and
F#1 means furnace area at point 1. The red circle shows that casting plant placed three fans at
pouring process and one fan at furnace.
lxiii All sample data were taken using Indoor Air Quality Monitor as shown in Appendix
C.
Figure 4.5 Layout of pouring area.
lxiv 4.2.4 Questionnaires
There are 25 questions in the questionnaire form. Thirty-three forms were distributed
to all workers in all departments. The questionnaires are categorized in three categories, work
background, workplace environment and work safety. All feedbacks from the questionnaire
will be discussed in data analysis.
4.2.5 Observation
Figure 4.5 until Figure 4.10 shows the work environment at pouring area. Figure 4.5
shows the manual material handling. The height of is mold 15 cm from the ground.
Figure 4.6 Manual material handling
lxv Figure 4.7 Pouring process
Figure 4.8 Ventilation system
lxvi Figure 4.9 Pouring area
Figure 4.10 Furnace area
4.3
Data Analysis
4.3.1
Analysis of Questionnaire
lxvii 4.3.1.1 Work Background
Table 4.4 shows background of workers such as gender, age, race, education, working
experience, smoking status and safety training. All results are described in Appendix B.
Table 4.4 Background of workers
BACKGROUND ( WORKER CHARACTERISTICS ) CHARACTERISTICS MALE Number of Workers Age ( years ): Min Max Race: Malay Indian Education: Primary Secondary College / IKM Experience in Occupation: < 1 years 1 ‐ 5 years 6 ‐ 10 years > 11 years Smoking Status: Yes No Received Safety Training: Yes No 4.3.1.2 Workplace Environment
FEMALE 30 3 27 32 50 35 29 1 1 2 1 24 1 2 5 0 0 5 18 0 2 1 7 0 2 0 27 0 10 20 1 2 lxviii Workplace environment is the second questionnaire. There have Seven types of
hazards are asked: back injury, hot environment, dust, poor ventilation, lighting, noise and
chemical hazard. All data from questionnaire are analyzed and summarized in Table 4.5.
Back injury is main problem because they need to lift and carry heavy object such as the
mold. The second problem is hot environment especially at pouring process and furnace,
followed by dust and poor ventilation. Other problems are lighting, noise and chemical
hazard. Table 4.5 summarized the hazards.
Problems
Back injury
Hot environment
Dust
Poor ventilation
Lighting
Noise
Chemical hazard
Table 4.5 Types of problem
Number of workers
Number of workers
( 33 workers)
( in percentages)
30
27
25
18
10
5
3
90.91%
81.82%
75.76%
54.55%
30.30%
15.15%
9.09%
Figure 4.11 Pareto diagram on types of problem
lxix Table 4.6 shows the number of injuries by job categories. There are seven job
categories which are hot metal works, mold making, coating, shakeout, sand casting,
coremakers and grinders. Mostly accident occurs at hot metal works and mold making.
Table 4.6 Number of injuries by job categories
Job categories
Number of workers
(Accident/Injury)
( 33 workers)
Hot metal work
Molders
Coating
Shakeout
Sand blasting
Coremakers
Grinders
Pattern makers
Heat treatment
17
13
8
7
6
4
4
2
1
Figure 4.12 Pareto diagram for number of injuries by job categories
lxx Table 4.7 shows the number of frequency of accident. This data extracted from
Table 4.7.The highest number of injuries occurs at hot metal works followed mold making
and shakeout, coating, grinders and coremakers
Table 4.7 Frequency of accident
Number of workers
Frequency of
injured
Hot metal work
Molders
Shakeout
Coating
Grinders
Coremakers
Sand blasting
Pattern makers
Heat treatment
1x
2x
3x~5x
6x~10x
>10x
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
3
0
0
2
3
0
2
0
1
0
1
0
1
1
0
0
0
0
0
0
0
11
7
5
4
2
1
1
0
0
Figure 4.13 Pareto diagram of accident frequency
lxxi Workplace environment is the second categories in the questionnaire. There were
seven types of health hazards which are back injury, hot environment, dust, poor ventilation,
lighting, noise and chemical hazard.
4.3.1.3 Work Safety
Third categories in the questionnaire are work safety and focused on safety hazards
and personal protective equipment (PPE). PPE is important to protect workers from any
accidents. Table 4.8 shows seven types of PPE such as safety boots, gloves, goggles, mask,
apron, ear protection and face shield. Most workers wear safety boots at the plant
Table 4.9 shows the data for parts of body which are in accidents are injured. There
are nine job categories: pattern markers, molders, core makers, coating, hot metal works,
shakeout, grinders, sand blasting and heat treatment. Nine parts of body frequently injured
are head/hair, face, eye, nose, ear, finger, hand, body and leg. The data shows that most
workers obtain have injury at the head, body and hand at hot metal work.
lxxii Table 4.8 Number of workers using PPE
PPE
Number of workers using PPE
Safety boot
33
Gloves
12
Googles
11
Mask
3
Apron
2
Ear protection
1
Face shield
0
Figure 4.14 Pareto diagram on the number of worker using PPE
lxxiii Table 4.9 Data for injured body parts
Number of workers
Part
of
Hot
Pattern
Core
Sand
Heat
body
Molders
Coating metal Shakeout Grinders
makers
makers
blasting treatment
injured
work
head/
0
1
0
0
15
1
1
1
1
hair
face
1
1
1
1
2
5
1
2
0
eye
1
3
1
1
0
25
0
6
0
nose
0
4
1
0
0
25
0
4
0
ear
0
7
1
0
0
15
0
1
0
finger
1
8
4
6
10
5
2
3
0
hand
1
16
4
9
15
5
3
5
1
body
0
4
4
0
15
4
4
0
0
leg
0
8
4
5
8
2
1
1
0
4.3.2
Analysis of Indoor Air Quality Monitor
All temperature measurements were taken using Indoor Qir Quality Monitor as
summarized in Figure 4.15, Table 4.10 and Table 4.11. The range of temperature was
classified into four different colours; red for hot temperature above 43ºC, green for
temperature above 42ºC, blue for temperature above 41ºC, and purple for temperature below
40ºC. The results show that purple indicate low temperature of less than 40ºC because closes
with window and fan (see Figure 4.5).
lxxiv Figure 4.15 Layout of pouring area with ambient temperature
Table 4.10 Temperature at pouring area
LOCATION & POINT AT POURING
#1
#2
#3
#4
#5
#6
#7
#8
DSB_A
34.45
35.20
35.50
36.15
36.65
37.05
37.45
37.88
DSB_B
31.05
39.30
39.55
40.05
40.85
41.25
41.65
41.95
DSB_C
42.00
42.35
42.65
42.50
42.35
43.00
43.00
43.10
DSB_D
42.80
42.80
42.90
43.10
43.00
43.50
43.30
43.40
DSB_E
42.05
42.40
42.60
42.70
42.80
42.90
43.00
43.00
DSB_F
42.45
42.55
42.65
42.70
42.70
42.70
42.75
42.75
DSB_G
42.30
42.40
42.55
42.60
42.65
42.70
42.75
42.80
DSB_H
41.55
41.80
41.85
41.90
42.00
42.10
42.20
42.25
lxxv Table 4.11 Temperature at Furnace
LOCATION & POINT AT FURNACE
F# 1
F#2
F#3
F#4
F#5
F#6
F#7
F#8
41.80
41.80
41.93
42.10
42.20
42.35
42.85
43.00
F#9
F#10
F# 11
F#12
F#13
F#14
F#15
F#16
43.55
43.30
43.10
42.45
42.60
42.70
43.25
43.65
F#17
F#18
F#19
F#20
F#21
F#22
F#23
F#24
43.50
43.25
42.85
42.50
42.40
42.30
42.00
42.10
4.3.3
Analysis of Observation using HIRARC
The purpose of HIRARC is to identify all the factors that may cause harm to
employees and others. Figure 3.1 shows the flowchart of HIRARC process. Table 4.12 shows
the HIRARC pouring process which is determined potential hazard, severity, likelihood and
risk of each activity at pouring process. At the pouring process have three major activities;
prepare the molten metal, scooped perlite and poured into furnace to remove foreign particles
and poured molten metal into mold solidification. The indicator of colour red and yellow
showed in Table 2.1 until Table 2.4.
lxxvi Table 4.12 HIRARC of Pouring Process
No
Activity
1.
Prepare the
molten metal
2.
Scooped
perlite
and
poured into
furnace
to
remove
foreign
particles
3.
Poured
molten metal
into mold for
solidification
Potential Hazard
Severit
y
Like
lihood
Risk
1. Sharp edge from scrap
2
4
8
2. Sparks / dust from
furnace
3
5
15
3. Toxic waste
4
2
8
4. Heavy metal
contamination
3
3
9
5. Splash from molten metal
4
3
12
1. Extreme heat and
temperature
2
5
10
2. Fumes from furnace
3
4
12
3. Explosions while
equipment failure
5
2
10
1. Sparks hot metal
3
5
15
2. Back injury while poured
3
5
15
3. Dust
3
4
12
4. Fumes from molten
metal
3
4
12
5. Explosion
5
4
20
6. Leg injury while mold
failure
3
4
12
7. Hand injury while carry
weighted into mold
3
5
15
lxxvii 4.4
Problem Identification
After data collection and analysis casting plant has two main hazards.
i.
Working condition not ergonomic which can cause back injury and hand injury due to
poor material handling while pouring.
ii.
4.5
Poor ventilation which cause employees to be exposed to dust, fume, glare and heat.
Summary
From data collection and analysis, pouring area has two main hazards which are
material handling and ventilation. There is no mechanized material handling to minimize
back injury. At pouring area, the workers exposed to dust, fume, glare and extreme heat due
to insufficient ventilation.
lxxviii CHAPTER 5
PROPOSED SOLUTIONS
5.1
Introduction
This chapter discussed proposed solutions to control health hazards at pouring area.
5.2 Proposed Solution
To ensure that the hazards identified can be controlled, two proposed solutions are
developed for the each of the hazards.
i.
Poor material handling – the main cause of this problem is the workers have to use
manual handling during pouring of molten metal. Replacing manual material handling
with pouring trolley and can minimize back injury.
The pouring trolley can carry molten metal up to 35kg – based on Finite Element Analysis.
lxxix ii.
Poor ventilation system – the can cause too much dust, smoke and heat at pouring
area especially around the furnace.
Install ventilation system at pouring area to minimize heat and dust.
5.2.1 Proposed Solution for Manual Handling
Manual material handling has been known to be one of the prime causes of back
injury. Many of these injuries arise from improper handling of materials. The direct and
indirect costs are enormous, and the human suffering associated with low back injuries is
immeasurable (Kroemer et al., 2001). In order to control the frequency and severity injuries, a
pouring trolley has been proposed to replace manual handling.
5.2.1.1 Pouring Trolley Design.
Pouring trolley can be used at the casting plant to replace manual pouring. Figure 5.1
shows the design of pouring.
The material selected for the pouring trolley is carbon steel. The steel has good
mechanical properties and cost effective. The dimension of this part is 1000 mm L x 500 mm
W x 750 mm H. The height of the trolley is at the waist of the workers according to ISO Std
7250, Body Human Measurement. The width of trolley is based on length and width of the
mold. The design require a table to place the mold which is 15cm (see Figure 5.2).the Figure
5.2 shows the technique to pour the molten metal using the trolley.
lxxx The ladle is the same one currently used at the company. (Figure 5.3).Different size of
ladle can be used with the trolley for weight range between 35 kg to 70 kg. Tungsten inert gas
welding (TIG) is used to fabricate the pouring trolley.TIG welding is suitable especially for
thin metals. The cost of the inert gas makes this process more expensive but provides welds
with very high quality and surface finish.
The advantages of using pouring trolley is that the workers do not need to bend their
body while pouring molten metal into the mold, The workers only need to stand, hold the
ladle and turn to the left/ right simultaneously. After that, the workers can move ladle and
pour or again until the molten metal is finished.This way back pain can be reduced.
Figure 5.1 Pouring trolley design
lxxxi Figure 5.2 Methods when using pouring trolley.
Figure 5.3 Types of ladle
5.2.1.2 Analysis of Pouring Trolley
lxxxii The design of the pouring trolley is analyzed using MSC Patran Version 2005 The
pouring trolley is analyzed using static analysis. The model consists of carbon steel angle iron
20 mm by 20 mm width and 3 mm thickness.. The dimension of the pouring trolley is 1000
mm length and 500 mm width and750 mm height. First step is to prepare the model geometry
and then define the materials, define the properties of the elements, mesh the geometry, and
then apply the constraints and loads (see Appendix F.
Figure 5.4 Result of stress analysis of pouring trolley design
Figure 5 shows the stress analysis for the pouring trolley. Load is placed in the middle
of the trolley and gradually increased until it reached the point of failure.
lxxxiii Table 5.1 Finite element result
PROPERTIES IN NASTRAN
LOAD
(kg)
FORCE
(N)
MAX.
STRESS
(N/mm²)
MAX.
DEFORMATION
(N/mm²)
YIELD
STRENGTH
(255 N/mm²)
35
350 @ 175
121
4.63
PASS
45
450 @ 225
156
5.95
PASS
55
550 @ 275
191
7.27
PASS
65
650 @ 325
226
8.59
PASS
70
700 @ 350
242
9.24
PASS
75
750 @ 375
261
9.91
‘ FAIL ‘
85
850 @ 425
296
11.23
‘ FAIL ‘
95
950 @ 475
331
12.55
‘ FAIL ‘
100
1000 @ 500
347
13.2
‘ FAIL ‘
200
2000 @ 1000
693
26.4
‘ FAIL ‘
Table 5.1 shows the finite element analysis of the pouring trolley using MSC/Patran.
This analysis starts with minimum load of 35 kg. To ensure a safe design, maximum stress
should be less than yield strength of carbon steel. The analysis start with 35 kg weight and the
maximum stress is 121.Tis trolley can support load range until 70 kg. The pouring trolley
start to fail when the load exceed 75 kg.
5.2.2 Local Exhaust Ventilation System
lxxxiv 5.2.2.1 Calculation and Analysis of Local Exhaust Ventilation System
All calculations of the ventilation system are based on Ductulator, English and SI
Metric units. The Ductulator is an accurate, easy-to-use calculating device that aids in the
design layout of air handling systems, sizing of ducts and reviewing the existing duct. With a
single setting, the dimensions of any duct size problem may be read directly from the face of
the Ductulator. Conversion of units, English-to-metric, or vice versa, is accomplished by
setting-up reading on the scales of one unit system, reversing sides of the Ductulator, and
reading the converted values from the scales of the other unit.
Ductulator English Units required air volume in CFM (outer blue and red bands) is
first established With only one of the four following factors known, the other three are found
from a single setting of the Ductulator.
i.
Friction in inches of water per 100’ of duct............... (inner blue band)
ii.
Desired velocity in feet/minute (FPM) in round duct...(inner red band)
iii.
Round duct diameter (inches)............................... (window)
iv.
Dimensions for rectangular ducts (inches).............. (green band)
Procedure: With the friction per 100’ of duct known, set this friction (inner blue band)
opposite required CFM (outer blue band). The resulting velocity in round duct (inner red
band) coincides with established CFM in outer band. Round duct diameter is indicated in
window by arrow. Various equivalent rectangular duct sizes are read from green bands.
Calculation for ventilation system based on Ductulator following below;
Dimension of space 45’ x 49’ x 15’ = 33075 ft³
lxxxv Ventilation standard for: Factory + Process + Heat = 10 air change/hour
Ventilation Air : Volume x 10 Ac/hr
= 330750 ft³/hr
= 5521.5 ft³/min
Six inlet @ 920 cfm/each
The required ventilation is 920 cfm from 6 inlets. The location of the inlet must be
very close to the source of contaminants.
5.2.2.3 Design of Local Exhaust Ventilation System Using AutoCAD 2002
Based on calculation and analysis, The local exhaust ventilation require with six inlets
with 920 cfm/each.
The LEV is capable to remove odors, fumes, dust and heat from an enclosed occupied
space. Such exhaust may be of the natural variety or may be mechanical by means of roof or
wall exhaust fans or mechanical exhaust systems.
Figure 5.14 shows the plan view of local exhaust ventilation system and Figure 5.15
shows the front view with the dimension. Each inlet will suck out air 920 cfm. Initially, two
inlets will remove air 920 cfm through the duct with 10.inch’ diameter ducting pipe. Initially
and at the second stage at pouring process, the air will flow out through duct size of 12.inch’
diameter ducting pipe because the air inside is flowing at1840 cfm. The duct size at second
stage is bigger than the first one because of increasing volume of air 1840 cfm. The third
stage is at the furnace area where the duct size is 12.inch’ diameter. Each inlet at the furnace
will remove 920 cfm of air and will be joined together with air inlet from pouring area. The
lxxxvi total volume of ventilation air is 5520 cfm and passing through the duct size of 16’ inch
diameter and 18’inch diameter passing through the exhaust fan with capacity 5520 cfm.
Figure 5.5 LEV ducting design
lxxxvii Figure 5.6 LEV location
Figure 5.16 shows the design of local exhaust ventilation system at pouring area. The
location of LEV is based on data collection and analysis. The LEV inlet is installed at area
where the temperature is above 43°C.
lxxxviii Figure 5.7 Location of LEV with respect to ambient temperature.
5.3
Summary
This chapter has discussed the proposed solutions to reduce hazards at the casting
plant. The use of pouring trolley can minimize back pain . The installation of local exhaust
ventilation can reduce extreme heat and dust from the sand casting process.
lxxxix CHAPTER 6
CONCLUSIONS AND FUTURE WORKS
6.1 Introduction
This chapter discuss conclusions of this project. The first part summarizes the project and
the second part is recommendation for future works.
6.2 Conclusion
This project study health hazards at casting plant, namely manual handling and heat
stress. This project started with review of the literature, questionnaire survey and observation
at the casting plant to identify health hazards.
The first objective of the project is to identify health hazards and assess risk and develop
control measures. Data collections are done through survey, observation and indoor air
temperature measurement, data analysis, two problems were identified which are manual
handling and heat stress. Two proposed safety improvements were developed. Pouring trolley
xc was recommended to replace manual pouring to minimize back pain. This pouring trolley can
also increase productivity. Local exhaust ventilation was recommended based on Indoor Air
Quality Monitor data and analysis. The result showed that the temperature at pouring area is
around 43.40ºC and a ventilation system is needed to replace the fan and suction fan. Local
exhaust ventilation can reduce heat as well as dust.
The use of pouring trolley and installation local exhaust ventilation can improve health
and safety at the casting plant.
6.3 Recommendations for Future Works
In this project, the focus on safety and health improvement is at sand casting process
only. Future works should be directed to other improvement strategies and create a better
working environment. The following are recommendations for future work;
i.
Study on the possibility of automating the pouring process.
ii.
Conduct a comprehensive audit for the casting plant.
iii.
Carry out force analysis for all manual operations.
iv.
Study on bio-mechanics of the workers.
xci REFERENCES
1. Tycho K. Fredericks, Anil R. Kumar, Sadat Karim, An Ergonomics Evaluation of a
Manual Metal Pouring Operation, 2008, 182-192.
2. Guidelines for Hazard Identification, Risk assessment and Risk Control (HIRARC),
Department of Occupational Safety and Health , Ministry of Human Resources,
Malaysia, 2008. JKPP DP 127/789/4-47.
3. Karim, S. Fredericks, Physiological cost of manual metal pouring operations. 1998,
29-33.
4. Itasca , National Safety Council (1994), Accidents Facts.
5.
Farhang A.K and Michael S.B, Comfort of personal protective equipment, Applied
Ergonomics , Vol.26, 1995,195-198.
6. Tasneem Abbasi, S.A. Abbasi, Dust Explosions- Cases, causes, consequence and
control.
7. Chaffin, D.B, Manual material handling and the biomechanical basis for prevention of
low back pain in industry.1987, 989-996.
8. Gettysburg College (February 2, 2007)., Personal Protective Equipment Program.
9. Purdue University (February 14, 2003)., Personal Protective Equipment(PPE) Policy.
2-5.
10. Breish, S. B, What is ahead? , Dec 1989, 48-52.
11. Ames Health and Safety Procedures and Guidelines (2004), Chapter 33- Personal
Protective Equipment (PPE) Hazard Assessment and Selection (REDACTED).2-24.
12. T.Myers, AIbaretta, Investigation of the Jahn Foundry and CTA Acoustics dust
explosions: similarities and differences , 2009,1-6
xcii 13. Conita H.S Lam. Appropriate Personal Protective Equipment for Isolation, Speakers
Abstracts/ International Journal of Antimicrobial Agents 26S (2005) S1-S63, page
S44.
14. Kroemer. K.H.E, 2001, Ergonomic: How to Design for Ease and Efficiency. Prentice
Hall, Inc, New.
15. Terry Dell and Jan Berkhout, Injuries at a Metal Foundry as a Function of Job
Classification, Length of Employment and Drug Screening.
16. Anne Marie Feyer, Ann M. Williamson, David R. Cairns, The Involvement Of Human
Behaviour In Occupational Accidents: Errors In Context.
17. D.Garddner, J.A. Cross, P.N. Fonteyn, J.Carlopio, Mechanical Equipment Injuries in
Small Manufacturing Business.
18. Robert. S. Dungan , nikki H. Dees, The Characterization Of Total And Leachable
Metals In Foundry Molding Sands.
19. Karen A. Brown, Workplace Safety: A Call for Research.
20. Angela S.Blair, Dust Explosion Incidents and Regulations in the United States
21. H-w Kuo, C L Chang, J S Lai, F C Lee, B V Chung, C J Chen, Prevalence of and
Factors Related to Pneumoconiosis among Foundry Workers in Central Taiwan.
xciii APPENDIX A
DSB CASTING SDN BHD
QUESTIONNAIRE FOR DATA COLLECTION OF THE PROJECT
xciv Thesis title: OCCUPATIONAL SAFETY AND HEALTH AT A CASTING
PLANT
A. LATAR BELAKANG PEKERJA NAMA: JANTINA : LELAKI BANGSA : MELAYU PEREMPUAN INDIA UMUR: 18 ‐ 20 TAHUN 21 ‐ 30 TAHUN 31 ‐ 40 TAHUN 45 TAHUN KEATAS 5 ‐ 10 TAHUN 10 TAHUN KEATAS LAMA BEKERJA: KURANG 1 TAHUN 1 ‐ 5 TAHUN Tahap pendidikan sekolah rendah sekolah menengah kolej / university / politeknik tidak bersekolah Lain‐
lain : Adakah anda dilindungi Insuran? YA TIDAK Adakah anda merokok? YA TIDAK B. JENIS KEMALANGAN 1. Terangkan bahagian yang anda bekerja dan xcv lakukan. membuat pattern membuat campuran green sand / silica sand membuat dan menyediakan mold membuat dan menyediakan core memanaskan mold menyediakan cecair besi panas menuangkan cecair besi panas kedalam laddle menuangkan cecair besi panas kedalam mold mengeluarkan mold melakukan sand blast prosess heat treatment prosess grinding Lain‐
lain : 2. Adakah anda pernah mengalami kemalangan/kecederaan di tempat kerja sepanjang anda bekerja. YA TIDAK 3. Jika YA, berapa kali anda mengalaminya? 1 kali 2 kali 3 ‐ 5 kali 5 ‐ 10 kali lebih 10 kali tidak ingat kerana terlalu kerap berlaku setiap hari kadang‐
kadang 4. Jika YA, di bahagian kerja manakah yang anda mengalaminya? Penuangan (pouring) Moulding Grinding coremakers Lain‐
lain : 5. Jika penuangan (pouring) ,bahagian anggota yang mana pernah anda mengalami kecederaan xcvi kaki mata tangan anggota badan muka Lain‐
lain : 6. Jika moulding , bahagian anggota yang mana pernah anda mengalami kecederaan tangan dan jari hidung mata anggota badan Lain‐
lain : 7. Jika grinding ,bahagian anggota yang mana pernah anda mengalami kecederaan mata telinga anggota badan tangan dan jari muka Lain‐
lain : 8. Jika penuangan coremakers ,bahagian anggota yang mana pernah anda mengalami kecederaan tangan dan jari hidung mata anggota badan Lain‐
lain : 9. Jenis kemalangan / kecederaan yang pernah anda alami. cecair besi panas jatuh semasa menuang ke dalam mold Percikan besi cecair panas dari furnace semasa sedang mengacau xcvii di furnace Percikan besi cecair panas dari furnace semasa berdiri berhampirannya Percikan besi cecair panas dari furnace semasa menuang ke dalam ladle tersepak / terpijak cecair besi panas tangan /kaki / badan melecur akibat cecair besi melecur akibat dari gas / api semasa untuk panaskan mold jatuh akibat tersepak wire gas sakit mata disebabkan serpihan pasir / habuk telinga berdengung akibat bising dari prosess sand blast jatuh akibat tersepak wire gas mold jatuh menghempap kaki / tangan pattern jatuh menghempap kaki/ tangan kelukaan pada jari akibat mata pisau/ mata gergaji ketika memotong untuk membuat pattern pengsan akibat panas sesak nafas / hidung tersumbat disebabkan habuk percikan besi dari grinding machine Lain‐
lain : C.MASALAHKESIHATN 10. Adakah anda mempunyai masalah kesihatan? ADA TIADA 11. Jika ADA, sila jelaskan. sakit belakang sakit pinggang pening / sakit kepala pedih mata sesak nafas / asma sakit jantung darah tinggi kencing manis sakit leher sakit tekak / xcviii lenguh‐lenguh badan sakit sendi Lain‐
lain : bibir kering gatal‐gatal di tapak tangan pedih ulu hati 12. Merujuk kepada soalan diatas, berapa kali kah anda mengalami nya? tidak ingat kerana terlalu 1 kali kerap berlaku setiap 2 kali hari kadang‐
3 ‐ 5 kali kadang 5 ‐ 10 kali lebih 10 kali 13. Berapa kalikah anda menjalani ujian kesihatan dalam setahun? tidak ingat kerana terlalu 1 kali kerap berlaku setiap 2 kali hari kadang‐
3 ‐ 5 kali kadang Lain‐
5 ‐ 10 kali lain : lebih 10 kali D. ALAT KESELAMATAN 14. Adakah anda mengetahui akan kepentingan pemakaian alat / pakaian keselamatan? YA TIDAK 15. Adakah anda memakai pakaian / alat keselamatan semasa anda bekerja? YA TIDAK 16. Jika YA, apakah alat keselamatan yang anda gunakan semasa anda bekerja. safety boot googles apron gloves mask xcix ear protection face shield Lain‐
lain : 15. Jika TIDAK, sila jelaskan mengapa? 16. Adakah anda selesa dengan pakaian keselamatan yang disediakan? YA TIDAK 15. Jika TIDAK, sila jelaskan mengapa? c APPENDIX B
ANALYSIS FROM QUESTIONNAIRE
ci Question 1: Gender
Only 8% are females and the rest of them are males. This is because most of the work that
has to do needs energy and caution. Men are much better than women in this case. Three
women are suitable placed at core making area and doing the same work repetitively for the
whole day compared to men.
Question 2: Age
Most of the employees are in the range of 27 to 50 years old. There are 25% in the range of
fewer than 30 years old, 36% in the range of 31 to 49 years old and 4% in the range of more
than 50 years old.
Question 3: Race
At DSB Casting only 8% are India and the rest of them are Malay. The 8% India are 2
women and men.
Question 4: Education
Mostly of workers in level secondary school with 26 workers and the rest primary 20 and 5m
workers have certificate foundry from college Instituted Kemahiran MARA.
Question 5: Experience in Occupation
They have 70% worker have above six years working experienced, and the rest 15% for less
than five years and above 10 years. Mostly workers at DSB Casting start working at age 25
years old until their resign.
Question 6: Smoking Status
Only 90% of workers no smoking and the rest is smoker.
Question 7: Received Safety Training
Only 12 workers got safety training in year 1997 and after that no safety training for workers.
Twenty-two person did not have any safety training because their start working 1999.
cii APPENDIX C
MECHANICAL DRAWING OF POURING TROLLEY
USING SOLID EDGE V19
ciii civ cv APPENDIX D
MECHANICAL DRAWING OF LOCAL EXHAUST VENTILATION SYTEM USING
AUTOCAD 2002
cvi cvii cviii APPENDIX E
ANALYSIS OF POURING TROLLEY
USING MSC NASTRAN/PATRAN
cix The step to analyzed pouring trolley are explained following below;
Step 1: Create the Geometry
There is no need to sketch the pouring trolley drawing because the drawing has already been
drwn using Solid Edge V19. Figure 5.4 shows the geometry of pouring trolley imported from
Solid Edge V19.
Figure 5.4 Geometry element
Step 2: Define the Mesh Element
Define a mesh element and follows;
i.
Under the ELEMENTS menu; click CREATE; click MESH; click CURVE;
click BAR2. Then select the trolley structure located at each side and click
APPLY, and then the Figure 5.5 will show a beautiful mesh on trolley.
cx Figure 5.5 Mesh element
Step 3: Define the Material Properties
Define new material description and its properties (see Figure 5.6):
ii.
Under the MATERIAL PROPERTIES menu; click NEW; click NAME and
put material property 302_Stainless_Steel.
iii.
Click ISOTROPIC. Click MANUAL INPUT; click LINEAR ELASTIC; A
menu appears where LINEAR ELASTIC parameters can be entered; type
193000 on the command line for Elast Modulus and type 0.25 on the
command line for Poisson Ratio; click OK.
Figure 5.6 Material Element
Step 4: Define the Properties of the Element
Define property element as follows (see Figure 5.7 and Figure 5.8):
cxi i.
Under the PROPERTIES menu; click PROP. SETS BY; click NAME as LFrame-5 and press Enter. Click INPUT PROPERTIES; type L-Frame -1 on the
command line [Section Name]; type 302_Stainless_Steel as a Material Name;
type <1, 1, 1,> on the command line Bar Orientation.
ii.
Click BEAM LIBRARY; click L Shape; type 20 on the command line W
(width); type 20 on the command line H (height); type 3 on the command line
t (thick);click APPLY; click OK.
Figure 5.7 Properties element
Figure 5.8 Properties L-frame
Step 5: Apply the Constraint
cxii Create a pinned support condition, and apply it to the four nodes on the base of the trolley
structure as follows;
i.
Under the LOADS/BCs menu; click on four nodes at base structure. This fixed
the x and y degrees of freedom since their values are 0; click OK (see Figure
5.9)
Figure 5.9 Boundary condition element
Step 6: Apply the Load
Create a Load Case definition as follows:
i.
Under the LOADS/BCs menu; click FORCE. The force will apply at the
critical point.. Click the node at middle and type -175 on the command line
load and press the Enter key; click OK. (see Figure 5.10)
cxiii Figure 5.10 Load element
Step 7: Run the Analysis
Lastly, run the analysis. The Figure 5.11 shows the step run analysis.
i.
Under the ANALYSIS menu; click ANALYZE; click Trolley1; click
TRANSLATION PARAMETERS.
Figure 5.11 Initial analysis of trolley design
cxiv Step 8: Analysis the Result
The Figure 5.12 shows the step to run the result. The result analysis is shown in Figure 5.13.
i.
Under the RESULTS menu; click CREATE-QUICK PLOT; select
DEFAULT,A1:STATIC SUBCASE; select Fringe Result as BEAM
STRESSES, COMBINED; select Deformation Result as DISPLACEMENT,
TRANSLATIONAL.
ii.
Click VON MISES and result is displayed in Figure 5.13.
Figure 5.12 Stress analysis of pouring trolley design
cxv DISPLACEMENT VECTOR
POINT ID. TYPE
R3
T1
T2
T3
R1
R2
cxvi 1
G
1.568496E-02 -8.884762E-03 -5.080979E-02 3.088074E-05 -
7.384489E-03 5.329281E-05
2
G
-4.514838E-03 -9.128695E-03 -4.201461E-02 3.717214E-05 -
6.036044E-03 9.083922E-05
3
G
-2.120618E-02 -8.702318E-03 -3.328001E-02 3.039605E-05 -
4.687598E-03 2.522518E-05
5
G
-2.078333E-02 -1.619747E-02 -1.921013E+00
4.437195E-06
1.023476E-04 -5.102341E-06
6
G
-2.074328E-02
6.199344E-03
2.724707E-02 -2.152166E-05
6.094828E-03
3.532276E-02 -3.762795E-05
6.199692E-03
4.339705E-02 -2.151056E-05
4.639475E-03 -9.434270E-05
8
G
-4.844332E-02
5.881423E-03 -1.190370E-04
9
G
-7.650035E-02
7.123372E-03 -9.719852E-05
11
G
-3.259622E-02 -2.015395E-02 -4.628090E+00 4.685089E-06
2.062554E-04 -1.168873E-05
14
G
-4.096796E-01
2.978127E-03 -7.403460E-04 -1.456054E-05
2.199092E-04 -1.897302E-04
15
G
-2.505981E-01 1.183500E-03 -1.164328E-02 -5.356326E-06 -
1.570359E-03 -2.851177E-04
17
G
-9.856840E-02 6.870046E-04 -1.024386E-02 -4.722080E-06 -
1.416903E-03 -1.498444E-04
18
G
-2.178669E-04 2.850365E-04 -3.647083E-03 -3.407311E-06 -
4.635729E-04 -1.457101E-05
20
G
8.756898E-03
7.735272E-05
3.304133E-04 -1.909648E-06
9.970662E-05 -7.285931E-06
21
G
23
G
0.0
0.0
0.0
0.0
0.0
0.0
3.792720E-01 -4.235925E-03 -4.245300E-03 2.027745E-05 -
3.279264E-04 1.652024E-04
24
G
2.398621E-01 -1.713814E-03
8.225420E-03
8.175672E-06
7.835360E-03
6.831543E-06
1.482552E-03 3.051797E-04
26
G
9.242187E-02 -9.660599E-04
1.361531E-03 1.593638E-04
cxvii 27
G
-2.984942E-03 -3.881328E-04
2.153053E-03
4.727405E-06
4.260351E-04 1.354791E-05
29
G
-9.640392E-03 -1.036488E-04 -1.097667E-03 2.587516E-06 -
1.215902E-04 6.776451E-06
30
G
32
G
0.0
0.0
0.0
0.0
0.0
0.0
6.345974E-01 -4.316262E-03 -4.736545E-03 2.087397E-05 -
4.024069E-04 1.794377E-04
33
G
3.945341E-01 -1.712580E-03
1.438863E-02
8.425656E-06
1.342465E-02
6.860043E-06
3.967938E-03
4.652647E-06
2.432376E-03 3.055826E-04
35
G
1.534469E-01 -9.524553E-04
2.222679E-03 1.595777E-04
36
G
-2.613887E-03 -3.781517E-04
7.059533E-04 1.357279E-05
38
G
-1.480830E-02 -1.000940E-04 -1.476206E-03 2.514131E-06 -
1.795433E-04 6.786393E-06
39
41
G
G
0.0
0.0
-6.607168E-01
0.0
0.0
0.0
0.0
2.978920E-03 -7.561909E-04 -1.456387E-05
2.159287E-04 -1.911784E-04
42
G
-3.948740E-01 1.183490E-03 -1.773275E-02 -5.359364E-06 -
2.509030E-03 -2.851583E-04
44
G
-1.531415E-01 6.868471E-04 -1.560746E-02 -4.722452E-06 -
2.243459E-03 -1.498642E-04
45
G
1.841426E-03 2.849119E-04 -5.311208E-03 -3.406639E-06 -
7.203798E-04 -1.457019E-05
47
G
1.469798E-02
7.730399E-05
8.248095E-04 -1.908702E-06
1.754447E-04 -7.285095E-06
48
50
G
G
0.0
0.0
0.0
0.0
-1.727681E-03 -3.566413E-03
0.0
1.104540E-01
0.0
6.600470E-07
6.649723E-07 -7.530754E-07
53
G
-3.661147E-04 -3.564492E-03 1.776200E-01 6.230040E-07 -
1.030903E-05 -7.443236E-07
56
G
-3.227335E-01 1.353743E-03 -1.468820E-02 2.084334E-05 -
2.039694E-03 -2.901830E-04
cxviii 59
G
3.171729E-01 -1.913446E-03
1.132265E-02 -2.251766E-05
1.957464E-03 3.112375E-04
1
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
11
DEFAULT
0
SUBCASE 1
FORCES OF SINGLE-POINT CONSTRAIN
T
POINT ID. TYPE
T1
T2
T3
R1
R2
R3
21
G
-3.688019E+01 -8.658800E-02 8.889962E+01 3.401706E+01 -
2.412615E+03 2.448416E+00
30
G
3.722671E+01 9.397615E-02 8.614161E+01 -4.519904E+01
1.381623E+03 -2.277207E+00
39
G
5.924539E+01 7.894738E-02 8.669475E+01 -4.344424E+01
2.466862E+03 -2.280547E+00
48
G
-5.959192E+01 -8.633553E-02 8.826402E+01 3.399220E+01 -
3.599511E+03 2.448135E+00
1
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
12
0
1
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
13
DEFAULT
0
SUBCASE 1
STRESSES IN BEAM ELEMENTS
AM)
STAT DIST/
(CBE
cxix ELEMENT-ID GRID LENGTH
S-MAX
0
S-MIN
SXC
SXD
SXE
SXF
M.S.-T M.S.-C
1
1
0.000
4.069868E-01 5.200676E-01 -5.930145E-01 2.400245E-01
5.200676E-01 -5.930145E-01
2
1.000
-8.054476E-02 -6.245694E-02 9.340624E-02 -5.716529E-02
9.340624E-02 -8.054476E-02
0
2
2
0.000
-8.054476E-02 -6.245694E-02 9.340624E-02 -5.716529E-02
9.340624E-02 -8.054476E-02
3
1.000
-5.680763E-01 -6.449816E-01 7.798269E-01 -3.543551E-01
7.798269E-01 -6.449816E-01
0
3
3 0.000
1.820531E+01 -2.194369E+01 -2.363878E-01 2.146140E+01
2.146140E+01 -2.194369E+01
5 1.000 -6.331388E+01 7.363113E+01 -4.038732E-02 -7.436462E+01
7.363113E+01 -7.436462E+01
0
4
5 0.000 -6.331388E+01 7.363113E+01 -4.038732E-02 -7.436462E+01
7.363113E+01 -7.436462E+01
6 1.000
2.020381E+01 -2.495509E+01 1.556131E-01 2.397041E+01
2.397041E+01 -2.495509E+01
0
5
6
0.000
2.548371E-01 -6.611006E-01 2.142699E-01 3.861427E-01
3.861427E-01 -6.611006E-01
8
1.000
1.317709E-02 -1.567267E-02 -1.437187E-04 1.550644E-02
1.550644E-02 -1.567267E-02
0
6
8
0.000
1.317709E-02 -1.567267E-02 -1.437187E-04 1.550644E-02
1.550644E-02 -1.567267E-02
9
1.000
-2.284829E-01 6.297553E-01 -2.145573E-01 -3.551298E-01
6.297553E-01 -3.551298E-01
0
7
cxx 9 0.000
7.887415E+01 5.771891E+01 -9.028694E+01 5.667327E+01
7.887415E+01 -9.028694E+01
11
1.000
-1.212929E+02 -8.708267E+01
1.355088E+02 -
8.790418E+01 1.355088E+02 -1.212929E+02
0
8
11
0.000
-1.212929E+02 -8.708267E+01
1.355088E+02 -
8.790418E+01 1.355088E+02 -1.212929E+02
1 1.000
7.508926E+01 5.462256E+01 -8.580467E+01 5.402517E+01
7.508926E+01 -8.580467E+01
0
9
6 0.000 -4.880721E+01 -3.533889E+01 5.324588E+01 -3.551950E+01
5.324588E+01 -4.880721E+01
14
1.000
-2.685832E+01 -1.942482E+01
2.846526E+01 -
1.967481E+01 2.846526E+01 -2.685832E+01
0
10
14
0.000
-2.685832E+01 -1.942482E+01
2.846526E+01 -
1.967481E+01 2.846526E+01 -2.685832E+01
15
1.000
-4.909431E+00 -3.510760E+00
3.684641E+00 -
3.830120E+00 3.684641E+00 -4.909431E+00
0
11
15
0.000
-4.556433E+00 -3.500793E+00
3.426510E+00 -
3.517337E+00 3.426510E+00 -4.556433E+00
17 1.000
7.593354E+00 5.308337E+00 -1.029072E+01 5.253495E+00
7.593354E+00 -1.029072E+01
0
12
17 0.000
7.593354E+00 5.308337E+00 -1.029072E+01 5.253495E+00
7.593354E+00 -1.029072E+01
18 1.000
1.974314E+01 1.411747E+01 -2.400796E+01 1.402433E+01
1.974314E+01 -2.400796E+01
0
1
13
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
DEFAULT
14
cxxi 0
SUBCASE 1
STRESSES IN BEAM ELEMENTS
(CBE
AM)
STAT DIST/
ELEMENT-ID GRID LENGTH
S-MAX
S-MIN
18 0.000
SXC
SXD
SXE
SXF
M.S.-T M.S.-C
1.641637E+01 1.171301E+01 -2.025756E+01 1.162079E+01
1.641637E+01 -2.025756E+01
20 1.000
3.617637E+00 2.489609E+00 -5.841051E+00 2.368038E+00
3.617637E+00 -5.841051E+00
0
14
20 0.000
3.617638E+00 2.489609E+00 -5.841051E+00 2.368039E+00
3.617638E+00 -5.841051E+00
21
1.000
-9.181118E+00 -6.733767E+00
8.575459E+00 -
6.884734E+00 8.575459E+00 -9.181118E+00
0
15
3 0.000
4.684231E+01 3.339751E+01 -5.433645E+01 3.368222E+01
4.684231E+01 -5.433645E+01
23 1.000
2.537717E+01 1.783902E+01 -3.010486E+01 1.818559E+01
2.537717E+01 -3.010486E+01
0
16
23 0.000
2.537717E+01 1.783902E+01 -3.010486E+01 1.818559E+01
2.537717E+01 -3.010486E+01
24 1.000
3.912024E+00 2.280527E+00 -5.873264E+00 2.688955E+00
3.912024E+00 -5.873264E+00
0
17
24 0.000
3.533267E+00 2.294182E+00 -5.610172E+00 2.347614E+00
3.533267E+00 -5.610172E+00
26
1.000
-8.648341E+00 -6.541023E+00
6.445472E+00 8.144774E+00 -8.648341E+00
0
18
8.144774E+00 -
cxxii 26
0.000
-8.648341E+00 -6.541023E+00
8.144774E+00 -
6.445472E+00 8.144774E+00 -8.648341E+00
27
1.000
-2.082995E+01 -1.537623E+01
2.189972E+01 -
1.523856E+01 2.189972E+01 -2.082995E+01
0
19
27
0.000
-1.773256E+01 -1.313750E+01
1.840794E+01 -
1.300074E+01 1.840794E+01 -1.773256E+01
29
1.000
-4.812584E+00 -3.828590E+00
3.855976E+00 -
3.659899E+00 3.855976E+00 -4.812584E+00
0
20
29
0.000
-4.812586E+00 -3.828588E+00
3.855976E+00 -
3.659902E+00 3.855976E+00 -4.812586E+00
30 1.000
8.107374E+00 5.480334E+00 -1.069599E+01 5.680925E+00
8.107374E+00 -1.069599E+01
0
21
1 0.000
7.568437E+01 5.424486E+01 -8.685814E+01 5.451892E+01
7.568437E+01 -8.685814E+01
32 1.000
4.075219E+01 2.894489E+01 -4.743562E+01 2.929512E+01
4.075219E+01 -4.743562E+01
0
22
32 0.000
4.075219E+01 2.894489E+01 -4.743562E+01 2.929512E+01
4.075219E+01 -4.743562E+01
33 1.000
5.820019E+00 3.644929E+00 -8.013093E+00 4.071315E+00
5.820019E+00 -8.013093E+00
0
23
33 0.000
5.896005E+00 3.987474E+00 -8.276185E+00 4.056457E+00
5.896005E+00 -8.276185E+00
35
1.000
-1.366602E+01 -1.017480E+01
1.379704E+01 -
1.007025E+01 1.379704E+01 -1.366602E+01
0
24
35
0.000
-1.366602E+01 -1.017480E+01
1.007025E+01 1.379704E+01 -1.366602E+01
1.379704E+01 -
cxxiii 36
1.000
-3.322805E+01 -2.433706E+01
3.587027E+01 -
2.419695E+01 3.587027E+01 -3.322805E+01
0
25
36
0.000
-2.806955E+01 -2.060933E+01
3.005347E+01 -
2.047013E+01 3.005347E+01 -2.806955E+01
38
1.000
-7.517944E+00 -5.782425E+00
6.894378E+00 -
5.616424E+00 6.894378E+00 -7.517944E+00
1
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
15
DEFAULT
0
SUBCASE 1
STRESSES IN BEAM ELEMENTS
(CBE
AM)
STAT DIST/
ELEMENT-ID GRID LENGTH
S-MAX
0
S-MIN
SXC
SXD
SXE
SXF
M.S.-T M.S.-C
26
38
0.000
-7.517944E+00 -5.782425E+00
6.894378E+00 -
5.616424E+00 6.894378E+00 -7.517944E+00
39 1.000
1.303366E+01 9.044481E+00 -1.626472E+01 9.237286E+00
1.303366E+01 -1.626472E+01
0
27
9 0.000 -7.609445E+01 -5.505439E+01 8.401315E+01 -5.523432E+01
8.401315E+01 -7.609445E+01
41
1.000
-4.116262E+01 -2.975978E+01
4.459405E+01 -
3.000954E+01 4.459405E+01 -4.116262E+01
0
28
41
0.000
-4.116262E+01 -2.975978E+01
4.459405E+01 -
3.000954E+01 4.459405E+01 -4.116262E+01
42
1.000
-6.230782E+00 -4.465168E+00
4.784764E+00 5.174947E+00 -6.230782E+00
0
29
5.174947E+00 -
cxxiv 42
0.000
-6.326369E+00 -4.777972E+00
5.433078E+00 -
4.794712E+00 5.433078E+00 -6.326369E+00
44 1.000
1.278407E+01 9.060158E+00 -1.613225E+01 9.005212E+00
1.278407E+01 -1.613225E+01
0
30
44 0.000
1.278407E+01 9.060158E+00 -1.613225E+01 9.005212E+00
1.278407E+01 -1.613225E+01
45 1.000
3.189452E+01 2.289829E+01 -3.769759E+01 2.280514E+01
3.189452E+01 -3.769759E+01
0
31
45 0.000
2.677256E+01 1.919695E+01 -3.192199E+01 1.910472E+01
2.677256E+01 -3.192199E+01
47 1.000
6.099747E+00 4.284502E+00 -8.627434E+00 4.162956E+00
6.099747E+00 -8.627434E+00
0
32
47 0.000
6.099747E+00 4.284502E+00 -8.627434E+00 4.162956E+00
6.099747E+00 -8.627434E+00
48
1.000
-1.457307E+01 -1.062795E+01
1.466712E+01 -
1.077881E+01 1.466712E+01 -1.457307E+01
0
33
18 0.000
1.945773E+00 1.686835E+00 -1.027576E+00 1.538611E+00
1.945773E+00 -1.027576E+00
50 1.000
1.828843E+00 1.606609E+00 -8.982642E-01 1.453112E+00
1.828843E+00 -8.982642E-01
0
34
50 0.000
1.828843E+00 1.606609E+00 -8.982642E-01 1.453112E+00
1.828843E+00 -8.982642E-01
27 1.000
1.711913E+00 1.526383E+00 -7.689528E-01 1.367612E+00
1.711913E+00 -7.689528E-01
0
35
45 0.000
2.951922E+00 2.510175E+00 -1.423238E+00 2.361910E+00
2.951922E+00 -1.423238E+00
cxxv 53 1.000
2.967912E+00 2.526057E+00 -1.443837E+00 2.372428E+00
2.967912E+00 -1.443837E+00
0
36
53 0.000
2.967912E+00 2.526057E+00 -1.443837E+00 2.372428E+00
2.967912E+00 -1.443837E+00
36 1.000
2.983902E+00 2.541938E+00 -1.464437E+00 2.382946E+00
2.983902E+00 -1.464437E+00
0
37
15
0.000
4.030636E-01 1.130419E-01 -3.486743E-01 3.338062E-01
4.030636E-01 -3.486743E-01
56
1.000
1.756456E-04 -2.314391E-04 6.536594E-06 2.113419E-04
2.113419E-04 -2.314391E-04
0
38
1
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
16
DEFAULT
0
SUBCASE 1
STRESSES IN BEAM ELEMENTS
(CBE
AM)
STAT DIST/
ELEMENT-ID GRID LENGTH
S-MAX
S-MIN
56
0.000
SXC
SXD
SXE
SXF
M.S.-T M.S.-C
1.756456E-04 -2.314391E-04 6.536594E-06 2.113419E-04
2.113419E-04 -2.314391E-04
42
1.000
-4.027123E-01 -1.135048E-01 3.486874E-01 -3.333835E-01
3.486874E-01 -4.027123E-01
0
39
24
0.000
-4.734231E-01 -1.320486E-01 4.094436E-01 -3.921993E-01
4.094436E-01 -4.734231E-01
59
1.000
-9.816792E-04 2.883108E-03 -6.812462E-04 -1.516332E-03
2.883108E-03 -1.516332E-03
0
40
cxxvi 59
0.000
-9.816792E-04 2.883108E-03 -6.812462E-04 -1.516332E-03
2.883108E-03 -1.516332E-03
33
1.000
4.714597E-01 1.378148E-01 -4.108061E-01 3.891666E-01
4.714597E-01 -4.108061E-01
1
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
17
0
1
MSC.NASTRAN JOB CREATED ON 23-APR-10 AT 12:27:56
APRIL 23, 2010 MSC.NASTRAN 9/23/04 PAGE
18
cxxvii cxxviii cxxix