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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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