1. 1. Page1 The study of Occupational Health and Safety in Textile industry examines to promote Health and safety to the workers in Bangladesh, Dhaka. The Hazards and risk involved in the textile industry is high compared with other industries and least importance are given to textile industries. Most of accident do not come to the legal formalities. The People are not aware of Health & safety is due to the workers are uneducated and management not given importance due to promote OHS in Textile industry becomes a barriers in implementing OHS. The major hazards happen are physical, chemical, ergonomically & physiologically hazards along with these some of things which can create hazards are more working hours, improper ventilation. The RPN (Risk priority number) has been find out for all the hazards in the textile industry and FEA (fault tree analysis) is done for the hazard with highest RPN no. Keywords: occupational health safety, Hazards, risk, legal formalities, working hours, RPN ABSTRACT
2. 2. Page2 It is my pleasure to be indebted to various people, who directly or indirectly contributed in the development of this work and who influenced my thinking, behavior and acts during the course of study. I express my sincere gratitude to worthy placement head for who providing me an opportunity to go indristrial field. I also extend my sincere thanks to Dr. Sk.AkhtarAhmad who provided valuable suggestion and precious time a accomplishing my field visit report. Lastly, I would like to thank the almighty and my friend with whom I shared my day to day experience and received loss of suggestion that improved my quality of report. ACKNOWLEDGEMENT
3. 3. Page3 S.no. Contain Page no. 1. Acknowledge 2 2. Introduction 4-6 3. Objective of the study 7 4. Missionof visit 8 5. Type of hazards 9-13 6. Literature review 14 7. methodology 15 8. Data outcome 16-18 9. Suggestion 19-20 TABLE
4. 4. Page4 A textile is a flexible material c omprised of a network of natural artificial fibers often referred to as thread or yam. Textile are formed by weaving, knitting, crocheting or pressing fibers together. The textile industry ( also known is the united kingdom and Australia as the rag trade) is a term used for industry grew out of the industrial revolution in the 19th century as mass producting of clothing became a mainstream industry. By the 20th century the industry in the developed world had developed a bad reputation, often involving immigrants in illegal sweat shops full of people working on textile manufacturing and sewing machines being paid less then minimum wages. This trend has resulted due to attempts to protect existing industries which are being challenged by developing countries in south east Asia, the Indian subcontinent and more recently, central America. Whilst globalization has seen the manufacturing outsourced to overseas labor markets, there has been a trend to shift focus to the more white Collin associated industries of fashion design, fashion modelling and retail. The Garment industry of Bangladesh has been the key export division and a main source of foreign exchange for the last 25 years. At present, the country generates about $5 billion worth of products each year by exporting garment. The industry provides employment to about 3 million workers of whom 90% are women. Two non-market elements have performed a vital function in confirming the garment industrys continual success; these elements are: (a) Quotas under Multi- Fibred Arrangement1 (MFA) in the North American market (b) Special market entry to European markets Bangladeshs industrial base, which has remained stagnant over the past two decades, is very narrow, contributing to about 11.5 percent of the GDP (BBS, 2001). Within this narrow industrial sector, however, the ready-made garments (RMG) industry has flourished as its most dynamic sector. Since its modest beginning in the early 1980s, the industry has contributed to the economy appreciably in terms of employment, output, and foreign exchange earnings. Moreover, employing as it does more than 1 million young women, the industry has brought about a noticeable change in society as well as in intra-household gender relations. The phasing out of the MFA by the end of 2004, together with ever-increasing globalization, will exert intense competitive pressure on Bangladeshs RMG industry. As the future of the manufacturing sector and the overall economy crucially depends on the performance of this industry, a matter of serious concern is how far, and in what manner, the RMG industry will face up to the challenge of the post-MFA trading scenario. The textile industry in Bangladesh has been an important contributor to the economy for centuries, and today is one of the country's most crucial economic sectors. According to the country's Ministry of Textiles and Jute, its textile and apparel industry encompasses textile processes from spinning; weaving; knitting including hosiery and knit dyeing; dyeing and Chapter 1 1.1 INTRODUCTION
5. 5. Page5 finishing; yarn dyeing; and sewing thread; up to the final outputs, including ready-made garments and nonwovens such as technical textiles. According to the most recent Bangladesh Garment Manufacturers and Exporters Association (BGMEA) Statistical Report, Bangladesh's woven apparel exports increased by 1.8 percent in 2007 for a value of US$4.61 billion, while knitwear exports increased by 8.05 percent in the same year, for a value of US$4.74 billion. Data from the report suggest that in 2007, the sector overall experienced growth of 4.67 percent - a rate not quite as good as rates achieved in previous years, but reasonable compared to growth by regional competitors. Though exports of both woven garments and knitwear have increased substantially, helping the RMG sector maintain its role as a main contributor to Bangladesh's economy, a few other textile products show potential, as they recently have experienced considerable growth. According to the country's Export Promotion Bureau, in July 2008 over July 2007, home textiles exports increased by 55.19 percent, and terry towel exports increased by 34.4 percent. However, the biggest growth was in exports of textile fabric - though representing a very small part of total exports, it showed a massive 697.9-percent increase in exports in July 2008 over July 2007. Woven garments and knitwear mainly are exported to the European Union (EU) - which takes in approximately 60 percent of Bangladesh's total RMG exports - followed by the United States, which accounts for more than 32 percent of the total. For the first time in the RMG sector's history, knitwear exports exceeded woven apparel exports in 2007. Knitwear has become the dominant sub-sector in terms of quantity exported - with a national export share of 37.39 percent in FY 2006-07 - and it is steadily gaining share. Over time, the knitwear sector has become almost self-sufficient in terms of fabric and yarn supply, as a result of spinning factories growing at the same rate as the country's stitching capacity, therefore increasing fabric and yarn needs. Furthermore, as knitwear exports have increased, upstream supplier capacity has gradually increased correspondingly. As a result, domestic suppliers can provide 90 percent of the sector's total fabric requirement. In addition, the number of spinning mills has grown as knitwear exports have increased. Textile and RMG (Ready Made Garments) are leading export-led industries in Bangladesh, in respect of foreign currency earning and employment. Recently, in the past-MFA era, the composite knitting industries are playing the crucial roles in country's RMG sector. Among Them, It has been possible because of its multi-dimensional and epoch-making activities since its inception in 1998. The study of Delta Composite Knitting Industries Ltd in textile industry in Dhaka is studied by checklist method, questionnaire method, workers interaction. The Study monitor the Delta Composite Knitting Industries Ltd in textile industry includes five major sectors they are Ginning Industry Spinning Industry
6. 6. Page6 Weaving Industry Dyeing Industry Garment Industry The hazards are prioritized by the based on the RPN number. The RPN number is calculated by the multiplication of severity, probability and detect ability. RPN = Severity x probability x Delectability. RPN is calculated for all the hazards involved which is involved in the textile industry. The maximum value of risk priority number is 1000. The process involved in spinning indusries are mixing, blow room, carding, comber, drawing ,simplex, spinning, auto corner ,packing. The hazards are also controlled by Safety Audit Safety survey Identifying Hazards Risk Analysis Risk estimation Job safety analysis Safety promotion Emergency preparedness Safety sample Safety committee Safety inspection The Delta Group (Delta Accessories ltd.) The Delta is a composite unit, having knitting, dyeing, finishing and sewing units under a single roof. Beside, we have our own printing, embroidery and washing units on the same premises. All these unit work as an integrated whole to meet the buyer's stipulated time and need based demands. Paid up capital: 10 million Taka Average Annual Turn Over: 36 million us$ Location of the Delta Group: DCKIL The factory is located at kashimpur, Gazipur - 30 minutes drive from the Zia International Airport, Dhaka. The total factory space is 256,332 sq ft, including two 6-storied, one 5-storied and one 3-storied builiding. The factory arena is highly protected with boundry walls and private security guards. A camp of bangladesh govt's ansar force in also established within the premises to confirm cent per cent security.
7. 7. Page7 The main objective of the study is conducted due to the Reasons: Measure work environment issues such that noise, temperature, lighting humidity. To find out Hazards in the Textile and tell the accurate control measure. Detect unsafe working condition in the Textile industries. To identify hazards in textile industry and provide with appropriate remedial measures To identify areas in which the hazards are involve. To identify how to industry can made free from risk. To give suggestion for avoiding the hazards. OUTCOME: To make working environment more safe and healthier. Immediate action must be taken to control this hazard to save workers health and promote safety. Regulations and procedures intended to prevent accident or injury in workplaces or public environments. Occupational safety and health (OSH) also commonly referred to as occupational health and safety(OHS) or workplace health and safety (WHS) is an area concerned with the safety, health and welfare of people engaged in work or employment. OSH may also protect co-workers, family members, employers, customers, and many others who might be affected by the workplace environment. In the United States the term occupational health and safety is referred to as occupational health and occupational and non-occupational safety and includes safety for activities outside work. Occupational safety and health can be important for moral, legal, and financial reasons. In common-law jurisdictions, employers have a common law duty (reflecting an underlying moral obligation) to take reasonable care for the safety of their employees, Statute law may build upon this to impose additional general duties, introduce specific duties and create government bodies with powers to regulate workplace safety issues: details of this will vary from jurisdiction to jurisdiction. Good OSH practices can also reduce employee injury and illness related costs, including medical care, sick leave and disability benefit costs. REMEDIALMEASURES Remedial Measures means taking steps to alleviate something we don't desire to experience. 1.3 Define Health And Safety? 1.2 OBJECTIVE
8. 8. Page8 The study of industrial Hazard and Safety in Textile industry examines to promote Health and safety to the workers in Bangladesh. The Hazards and risk involved in the textile industry is high Compared with other industries and least importance is given to textile industries. Most of accident does not come to the legal formalities. The People are not aware of Health & safety is due to the workers are uneducated and management not given importance due to promote OHS in Textile industry becomes a barriers in implementing OHS. The major hazards happen are physical, chemical, ergonomically & physiologically hazards along with these some of things which can create hazards are more working hours, improper ventilation. The RPN (Risk priority number) has been find out for all the hazards in the textile industry and FEA is done for the hazard with highest RPN no. Major health and safety issue in textile industry 1.5 The Major Health and Safety Issues in the Textile Industry 1.4 Mission of visit EXPOSURETO COTTON DUST EXPOSURETO CHEMICALS EXPOSURETO NOISE ERGONOMIC ISSUES
9. 9. Page9 1.6 TYPES OF HAZARDS 1.6.1 PHYSICAL HAZARD it includes noise, fire, temperature etc. HAZARD REMEDIAL MEASURE Isolation of the machine and silencer must be kept Inverted drive control noise in ring frame Proper maintenance lubricating control noise Remark: moderate (3+3+3) Dust collector Proper house keeping Necessary PPE should wear by worker Remark: moderate (3+3+4) Proper lightening condition Keep your backbone straight while lifting load Pull the load as close to the body Lift and carry loads with straight arms Remark: very good (5+5+5) Restrict unauthorised person to do welding ACB ( Air circuit breaker), MCB (motor circuit breaker) Remark: fair (4+4+4) Proper ventilation condition Proper house keeping Remark: (4) NOISE (Noise induced hearing loss Tinnitus) DUST (Causes respiratory problems and causes Byssinosis, a disease caused by cotton dust) LIGHT (eye strain and glaring) LIFTING HEAVY WEIGHT (Muscular skeletal disorders) FIRE SAFETY HAZARDS Loss of life, damages to the equipment WELDING OPERATION (Spark ignition is very dangerous) ELECTRICAL SHORT CIRCUIT HAPPENS (If no trips occur it gets sparks and get fire VENTILATION (Ventilation cause suffocation) Cause respiratory disease Breathlessnessetc. PHYSICAL MECHANICAL ERGONOMICALLY CHEMICAL
10. 10. Page10 TEMPERATURE Impropertemperature Improperfoodstorage CLEANLINESS Improper floor Improper dust HUMIDITY Improper humidity Improper workplace ELECTRICITY FITTING HAZARD It includes short circuit etc. Improper earthing (trip occurs) Improper isolation (electric shock) Motor high speed rotating due to high voltage (causes problem to the machine) Usage of old wire (not proper current flow) Input power cable exceeds more output (cable melting and heated) Looping in the running line (electronics PCB) Electrical maintenance (ECB board check the connection grease the motor frequently) Moisture (proper wiring) Proper temperature maintenances Temperature kept in control ACB ( Air circuit breaker), MCB (motor circuit breaker) Remark: (4+4+4= 12) Proper cleanness Maintenance floor to protect from hazard Necessary PPE should wear by worker Remark: (4+4+4= 12) Avoid improper temperature Avoid more humidity Manage proper temperature Remark: (5+5+5= 15) Avoid improper earthing and loose connections All circuits to be enclosed in a proper circuit Moisture to kept in control Circuit breaker must be individual Use of wires as per electrical standards Input wire must be more power than output Avoid looping Needs preventive maintenance Remark: fair (4) HAZARD REMEDIAL MEASURE
11. 11. Page11 1.6.2 ERGONOMICAL HAZARDS it includes Continuous work and improper workstations Uncomfortable work station and height (pain in hands and legs) Repetitive strain injuries (wrist, neck, shoulder, neck, knee, angle) Importance to ergonomics Proper working procedure Remark: poor (9) 1.6.3 PPE (Personal protective equipment) HAZARDS Not interested to work (physiological problem) Production target (stress to the worker) REMEDIALMEASURES Give counselling Set achievable target REMEDIALMEASURESHAZARD FEA for FireHazard in TextileIndustry 1.7 OVERALL
12. 12. Page12 All textile-manufacturing processes generate environmental pollution. Workers are exposed to the risk of breathing air polluted with dust and fly and contracting respiratory ailments, byssinosis (lung disease), chronic bronchitis etc. Cotton diseases called as Bygones is the most common problem found in ginning industry. To minimize the effect of these floating fibers or impurities, the humidified air which is circulated in the spinning and weaving department is filtered so as to separate these floating impurities from the air. The workroom should not be more than 0.2mgm3 and controlled by some specific task. The cotton dust should be dumped with proper care and avoid storing in open container. Excessive drying should be avoided, if it dry the cotton dust will fly fast 1.7.2 Air Pollution Created by Textile Machineries 1.7.1 FEA for Cotton Industry 1.7.3 REMEDIAL MEASURES
13. 13. Page13 Because of high spindle speeds reached on new machines (ring spindles up to 20000 rpm, rotor up to 110000 rpm) spinning mills can generally be assumed to generate a great deal of noise. Noise levels of 70 to 100 dB are commonly recorded in workrooms. However, permissible limit set up at 90 dB by Federal Standards of USA for maximum exposure duration of 8 hours per day. Noise level can be lowered by the use of noise control enclosures, absorbers, silencers and baffles and by the use of personal protective equipment (PPE), such as earmuffs. Where technical methods are insufficient, noise exposure may be reduced by the use of hearing protection By administrative controls such as limiting the time spent in noisy environment. Scheduling noisy operation outside normal shifts or at distant location. 1.7.4 NOISE LEVEL 1.7.5 REMEDIAL MEASURES
14. 14. Page14 The hazards happening in the Textile industries are Mechanical Hazards, physical hazards, chemical hazards, Ergonomic hazards and physiological hazards. Exposure of cotton disease called Bysinosis .The Symptoms are chest tightness, breaking problem, asthma and irritation in the Respiratory track. The study tells about the accumulation of workers, improper condition of the machine, ergonomic problem faced by the worker, dust problems, poor lighting, ventilation and unaware of personal protective equipment not given OHS in these industries. Education is the fundamental right that helps the Growth of nation. The education help the workers to get knowledge about medical rights, legal and social behavior. The people are uneducated most of them do not know OHS at work place . Ready made garment (RMG) are mass produced finished textile products of the clouthing industry. Some common types of RMG are shirt, paint, sweaters, t-shirt etc. orign of the RMG was after 1970 after the decreasing demand of jute industry. It took decades to stand itself as the leading profile making sector of our country. Today with many public and private organizers are giving the technological and other facilities for this sector as a result it is becoming strong and has shaped thus today. Mohammad salim zahargier, nimalathasan balasundaram (2010) mentioned in their paper that two main sources of economic growth of Bangladesh have manufacturing and servicing, both crucially dependent on the economic perforence of the country and another paper already say factors affecting employees perforence is RMG sector in Chittagong, Bangladesh. The Company unaware and lack of OHS some of them are training, housekeeping, accident prevention ,hospital facility ,safety To control the noise level in the company premises and outside the company necessary action must be taken that noise regulation must be adopted. To maintain the quality and production, the health of worker is essential .The most important Hazard in occupational is noise. The Main cause of noise problem in the weaving and spinning industry is due to the poor design, overload and old machinery. Chapter 2 2 LITERATURE REVIEW
15. 15. Page15 5.1 GINNING INDUSTRY The cotton in a machine which is used to separate the cotton fiber from the seeds and the cotton send to the textile for making yarn. The one of main Hazard in ginning industry is fire, the causes of fire happens in the Ginning Industry are Electrical, Manmade Behavior, spark from the Machine and stored Raw cotton in sunlight and other causes 5.2 SPINNING INDUSTRY The textiles are fabricated into clothes. Noise is the main hazard in textile industry. The noise pollution (Regulation and control) rule 2000 in industrial area was 75db at Day Time [6 AM to 10 AM] and Night time [10 PM to 6 AM].The fire accidents occur in textile mills are often. The Hazards in the spinning mills are more compare to other sectors of textile industry because the Raw material cotton exposed to the fire easily. 5.3 Working and Living Condition of Worker 5.4 Overworked Labour Force All workers, whether they are willingly to work or non will to work they are forced to work for 12 hours. These 12 hours does not include overtime. Some workers complaint that they are forcing to work more than that time. As per Factories act 1948 under chapter -6 working hours of Adults in section 51, no worker should not work more than 48 hour in a week and compensation Holiday must be given for Extra working days. 5.5 Unprotected Working Condition As we know that inhalation of cotton fiber leads to BYSONIS. So it is compulsory to use Masks for these working Environment but no one following these safety Measure. As per factories act 1948, under chapter -4, under section 27 says, prohibition of employment of women and children near cotton opener. 1) Task observation 2) Accident ill health or near miss data. 3) Workplace inspections. 4) Job safety analysis. 5) Legal standards 6) Guidance; ILO, OSHA, ISO, HSE.. etc. 7) Consultation. Chapter 3 3.1 METHODOLOGY 3.2 How we observation
16. 16. Page16 Data are the raw materials for any study. Relevant data for the study were collected from only primary sources (Checklist.). Two types of primary data were collected in the study qualitative and quantitative. 1. Quantitative data: Data were gather from observation of worker activities. 2. Qualitative data: Data were collected from interview. Visited organizations profile Name of the organization : Delta Group (Delta Accessories ltd.) Year of establishment : 1998 Production : Garments and Accessories Raw material (s) use : Fabrics, dye and other accessories. Working shift : 2 shifts (day and night), 8 hours regular + 4 hours overtime every day. Man power: 5000 Section Male Female Total Office section 350 300 650 Production 1200 2350 3550 Engineering /Maintenance 450 50 500 Security 300 0 300 Total 2300 2700 5000 3.3 Data
17. 17. Page17 Total Assessment result Total Physical hazard in work place: Maximum score Minimum Score Assessed score 45+45+45 = 135 9+9+9 = 27 36+37+36= 109 Total Mechanical hazard in work place: Maximum score Minimum Score Assessed score 20+20+20= 60 4+4+4= 12 12+11+11= 34 Total Chemical hazard in work place: Maximum score Minimum Score Assessed score 25+25+25= 75 5+5+5= 15 15+15+15= 45 Total Ergonomical hazard in work place: Maximum score Minimum Score Assessed score 30+30+30= 90 6+6+6= 18 9+9+9= 27 Evaluation of result and Analysis Organisational total Hazard Maximum score Minimum score Assessed score 360 72 215 Overall organisational hazard score is 202 out of 360. So Assessed hazard is 59.722% which is more than the average and thats mean hazard situation is not worrying. Organisation should take into consideration that there are hazards they should minimize for the workers as well for organisations better functioning. If we look into specific hazard categories, it is clear that workers are working in hazardous situation. For Physical hazard: maximum score is 135 and hazard assessed score is 108 which mean good. Workers are working in good condition. Mechanical hazard: maximum score is 60 and hazard assessed 22. It is also good for the workers.
18. 18. Page18 Chemical hazard: maximum score is 75 and assessed hazard score is 45 which is average. Ergonomical hazard: maximum score is 90 and assessed hazard score is 27 which mean poor and workers are working in hazardous situation. PPE Use: Maximum score Minimum Score Assessed score 105 21 21 Evaluation and result of PPE use: Employee PPE facilities are poor. As above mentioned table shows the data that our listed facilities Overall organisation score is 21 out of 150. Therefore employee did not use PPE. Welfare of the Employee and Health Hygiene: Total facilities Available Not available 24 24 nil Employee welfare and facilities are good. As above mentioned table shows the data that our listed facilities are 24 (organisation should have) for the employee but in reality organisation is providing 24 facilities which are maximum.
19. 19. Page19 Upgrade the existing technology or apply BD-EPA act. It is an act to provide for the protection, conservation, rehabilitation and improvement of environment, for the prevention and control of pollution, and promotion of sustainable development. In order to reduce dust emission from machinery it is proposed to cover up the moving parts of machines, the proper maintenance and correct alignment of the gin machinery. Also OSHA standards can be used in textile industry of Bangladesh in order to improve the health and safety aspects of the labor. Noise level can be lowered by the use of noise control enclosures, absorbers, silencers and baffles and by the use of personal protective equipment (PPE), such as earmuffs. Permissible limit set up at 90 dB by Federal Standards of USA for maximum exposure duration of 8 hours per day. Where technical methods are insufficient, noise exposure may be reduced by the use of hearing protection By administrative controls such as limiting the time spent in noisy environment. Organisation/Industry should pay attention more on facilities they should provide In the industry, ergonomic hazard is very high; they (authority) should pay attention on it. Employees are not using PPE enough during work. It should be increased to ensure to minimize accidents of worker during work. Scheduling noisy operation outside normal shifts or at distant location. To minimize the effect of these floating fibres or impurities, the humidified air which is circulated in the spinning and weaving department is filtered so as to separate these floating impurities from the air. The workroom should not be more than 0.2mgm3 and controlled by some specific task. The cotton dust should be dumped with proper care and avoid storing in open container. Excessive drying should be avoided, if it dry the cotton dust will fly fast. The above presentation has demonstrated the hazards and risk involved and their remedial measures in the five main sector of textile industries Ginning Industry Spinning Industry Weaving Industry Dyeing Industry and Garment Industry but the spinning and ginning industries are highlighted more due to their immense impact on workers regarding health and safety. 4.2 SUMMARY Chapter 4 4.1 SUGGESTION
20. 20. Page20 The hazards involved in textile industries are mainly noise, dust, fire and electrical hazards are found by calculated RPN number, The RPN number is calculated by the multiplication of severity, probability and detect ability. RPN = Severity x probability x Delectability, comparing to other hazards the maximum RPN is found to be harmful to the workers. Immediate action must be taken to control this hazard to save workers health and promote safety. The presented study has demonstrated the hazards and risk involved in the spinning and ginning industries. The main hazards are noise, dust, fire and electrical hazards is found by calculated RPN number, comparing to other hazards the maximum RPN is found to be harmful to the workers. So Immediate action must be taken to control these hazard to save workers health and promote safety to worker. 4.3 CONCLUSION