Syntax Literate: Jurnal Ilmiah Indonesia
p–ISSN: 2541-0849
e-ISSN: 2548-1398
Vol.
7, No. 10, Oktober 2022
PROPOSED SOP
DESIGN FOR THE IMPLEMENTATION OF OHS TO FULFILL THE REQUIREMENTS OF ISO
45001:2018 CLAUSE 6.1 IN THE PRODUCTION DIVISION AT PT XYZ
Nusaibah,
Sri Widaningrum,
Sheila Amalia Salma
Faculty of Industrial Engineering,
Telkom University, Indonesia
E-mail:
[email protected], [email protected], [email protected]
Abstract
PT XYZ is a metal casting industry company, where in the
production process there are several potential hazards. The efforts made by the
company to overcome these potential hazards are to provide PPE facilities to
workers. However, the workers lack of self-awareness of OHS makes them not
comply with the use of PPE. Therefore, work accidents still occur in the
company. The methods used in the design proposal stage are FMEA and FTA. FMEA
and FTA are failure analysis methods, FMEA can also be used to assess failures
that occur. The stages of the two methods are integrated to then create a
process of hazard identification, risk assessment, and control. The proposed
design is in the form of a Risk Control SOP. The purpose of the Risk Control
SOP is to identify what hazards occur in the production process and assess the
level of risk, so that the company can provide appropriate controls for
existing hazards. The SOP was made to fulfill the requirements contained in
Clause 6.1 of ISO 45001: 2018 and PP No. 50 of 2012 concerning OHSMS. With the
Risk Control SOP, it is hoped that it can assist the company in improving the
company's OHSMS and the company can achieve zero accidents.
Keywords: OHSMS, Zero accident, ISO
45001:2018, FMEA, FTA.
A company in running its business must have OHS elements,
namely occupational health, security, and safety. The
presence of these three elements can make the company work optimally without experiencing
work accidents
Recorded in the 2023 BPJS Employment, the number of work
accidents has increased significantly from 2016-2022
Figure 1. Number of Occupational Accidets in Indonesia 2015-2022
(Source:
BPJS Employment 2023)
According
to Ahmad et. Al (2016) the increasing number of work accidents in Indonesia can
be caused by several factors which are divided into five, namely human factors,
tools/machines, materials, methods, and the environment
PT
XYZ is a metal casting and machining industry where the products produced are
bollards, manhole covers, water catchment grills, plant grills, lamp posts,
etc. There are several processes
in making these products, starting from the raw material selection process,
molding process, pressing process, casting process, lifting process, finishing
process, quality control process, and shipping process. In these processes,
there are several potential hazards that occur in the company, resulting in
work accidents. The following is a recapitulation of work accident data at PT
XYZ in 2019- 2022:
Figure 2. Total Work Accident Data 2019-2022 at PT XYZ
(Source:
PT XYZ)
In 2023, the company has
not yet recapitulated the work accidents that occurred, so the researchers only
used the data on work accidents in 2019-2022 that had been provided by the
company. The graph of the number of work accidents that occurred above states
that work accidents that occur fluctuate and tend to be small from 2019-2022. These work accidents occurred due to the
same factors every year, namely unsafe actions of workers. As a result, similar
work accidents still occur. Therefore, unsafe acts committed by workers that
result in work accidents that occur every year need to be taken as a preventive
measure so that unsafe acts by workers do not occur in the following year.
Because the same work accident factor (unsafe action) continues to recur every
year, if prevention is not taken, it is feared that the following year work
accidents with the same factors will occur again. In fact, if the company does
not take precautions, the company also cannot predict whether an accident with
the same factor will occur or not. As a result of the work accident, the
company experienced a decrease in productivity due to the status of employees
who were unable to work because of the accident that occurred. Another loss
incurred is the company spending money on work accident insurance.
In actual conditions, the
company has tried to implement OHSMS
in its production process by providing personal protective equipment, such as
gloves, safety clothes, safety shoes, and helmets for workers, but even though
the company has provided these facilities, there are still many workers who do
not comply with and support the company to optimize OHSMS on the grounds that if they wear
protective equipment when working it will feel hot. Another effort made by the
company so that workers participate in implementing OHSMS is to provide rewards
to workers who comply with OHS
rules, in the form of using PPE when in the production area and punishment to
workers who do not use PPE, but these efforts are still not successful.
Therefore, it can be said
that the company's efforts have not been optimal in implementing OHSMS, so it can also be said that the
company has not been able to implement zero accident. Zero accident is the
government's award to the company for implementing the OHS program properly.
When the OHS program
is applied correctly and appropriately, the possibility of work accidents can
be reduced or even completely eliminated. The zero-accident predicate must be
accompanied by “without
losing working time”
In terms of occupational
safety, the government established regulations related to the Occupational
Safety and Health Management System (OHSMS) in Government Regulation No. 50 Year 2012. Based on
point 1 of Article 5 of PP No. 50/2012, it states that every business is
obliged to implement OHSMS
in its company. OHSMS
in PP No. 50 of 2012 is a component of an organization’s overall management
system that aims to reduce the risks associated with activities in the
workplace and provide a productive and safe work environment where the
international standard for OHSMS
is known as ISO 45001: 2018. In implementing OHSMS, an OHS plan is needed which is
stated in Article 9 of Government Regulation No. 50 of 2012. Then as a
fulfilment of the OHS planning requirements based on Article 11 Paragraph 2 of
Government Regulation No. 50 of 2012, companies must conduct risk analysis,
hazard identification, and risk management. Therefore, to minimize work
accidents and optimize the company's OHSMS, the company can create an OHS SOP related to hazard
identification, risk assessment, and control.
ISO 45001:2018 can be
used as a specific guide to OHSMS.
ISO 45001:2018 is an international standard regarding Occupational Health and
Safety Management System (OHSMS). In addition, ISO 45001: 2018 can also be used
to manage risks and potential hazards arising from OHS, to obtain a safe and
healthy work environment that allows it to improve company performance. This is
in accordance with the existing problems, namely regarding the potential
hazards arising from OHS in the production process at PT XYZ. In ISO 45001:2018
Clause 6.1 requires that every organization must establish, implement, and
maintain procedures to identify ongoing hazards, assess risks, and establish
necessary controls. Therefore, to be able to make OHSMS in accordance with what has been
required in PP No. 50 of 2012 and ISO 45001: 2018 Clause 6.1 to minimize work
accidents, a Risk Control SOP design is needed. With this SOP design, it is
hoped that it can optimize OHS in the company, besides that it can help the
company achieve zero accidents.
Design systematics is a series of diagrams used as
problem solvers in this study where the diagram will explain how the process is
from beginning to end. In the preliminary stage, the first activity carried out
is to determine the formulation of problems that occur at PT XYZ. The
determination of this problem formulation is based on the results of direct
observation or field studies conducted by researchers at the company as well as
interviews with HRD PT XYZ. The next activity carried out by researchers after
determining the formulation of the problem, the objectives and benefits of the
research is to determine what methods will be used in designing Risk Control
SOP. Researchers conduct literature studies to find the right method for
designing Risk Control SOP so that existing problems get the right solution
(Hidayat & Alifah, 2022).
The next stage is the data collection stage, where the
data needed in this study is collected first, before the data will be
processed. In this study, the data needed was divided into three, namely:
a.
Primary Data
Primary
data is the main data needed in this study, where this data is obtained based
on observations on the company's production floor and interviews with company
owners/employees. The following is the primary data collection mechanism in
this study:
Table
1
Primary
Data Collection Mechanism
|
Data Type |
Data |
Tools |
Mekanism |
Duration |
|
Primary
Data |
Actual Condition of the Company |
Observation and Interview |
Observation is carried out by observing the company's
production area, then recording what processes and activities are carried out
when the production process takes place. In addition, the interview process
was carried out face-to-face directly with HRD and several company production
staff. The interview process was carried out by providing several questions
related to the production process that researchers did not understand. |
2 days |
|
Production
Process |
b.
Secondary Data
Secondary
data is supporting data obtained from external sources that have credibility,
such as journals. In this study, the supporting data needed to support this
research was obtained through the company. The following is the secondary data
collection mechanism in this study:
Table
2
Secondary
Data Collection Mechanism
|
Data Type |
Data |
Tools |
Mekanism |
Duration |
|
Secondary
Data |
Company
profiles |
Literature Study |
Literature study is carried out by obtaining the
required documents (company profile, company vision and mission,
organizational structure, and work accident data) in the company through the
company's HRD. |
1 Days |
|
Company
Vision and Mission |
||||
|
Organizational
structure |
||||
|
Work
Accident Data |
The next stage carried out
after data collection is the processing of all data that has been collected. The following are done in data
processing:
a.
Create a process flow map based on production
process data. Process flow maps are used to clearly find out what activities are
carried out during the production process. In addition, process flow maps can
be used to clearly identify what things have potential hazards.
b.
Integrate all clauses of ISO 45001:2018 with PP No.
50 of 2012. The requirements of all clauses of ISO 45001: 2018 and PP No. 50 of 2012
are obtained by means of literature studies. Integration is carried out by
combining all ISO 45001: 2018 requirements with PP No. 50 of 2012 requirements,
so that the results of OHS implementation requirements in accordance with ISO
45001: 2018 and PP No. 50 of 2012 are obtained. The results of the OHS implementation requirements in
accordance with ISO 45001: 2018 and PP No. 50 of 2012 are then analyzed with
the actual conditions of the company, if a gap is found, a proposal related to OHS can be made.
c.
Identify the GAP between the company's actual condition
and the corresponding clauses based on the results of the integration of all
clauses of ISO 45001: 2018 and PP No. 50 of 2012. So that the output that will be
obtained later is in the form of GAP analysis.
The next stage after data processing
is the SOP design stage for the implementation of OHS to identify hazards, risk
assessment, and control. To arrive at the SOP design activity stage, the
implementation of OHS will be carried out using the stages of the Failure Modes
and Effects Analysis (FMEA) and Fault Tree Analysis (FTA) methods. Furthermore, this verification stage is
carried out to check whether the proposed SOP design for hazard identification,
risk assessment, and risk control that has been made is in accordance with the
reference or reference used, namely the requirements of ISO 45001: 2018 and the
requirements of PP No. 50 of 2012.
While in the validation stage,
this is a description of feedback from stakeholders related to the results of
the SOP design for hazard identification, risk assessment, and control. If the
design results are in accordance with the needs of the company, then proceed to
the analysis stage of the design results. As for this stage, an analysis of the proposed
design, namely the draft Risk Control SOP for hazard identification, risk
assessment, and control where this SOP design is made to meet the requirements
of ISO 45001: 2018 and PP No. 50 of 2012.
This closing stage is the last
step of this research, where there are conclusions from the results of the
research and suggestions addressed to the company, readers, and further
researchers.
1. Purpose of the Process
In
a process, it is important to have a goal. The objective of the process is something
that is to be achieved or produced from the process. The following are the objectives of the hazard identification,
risk assessment, and control process:
a.
Knowing the classification of hazards or
risks that occur during the production process.
b.
Knowing the level of risk based on the
risk assessment that has been carried out.
c.
Knowing what actions need to be taken to
control the risks that occur based on the identification and assessment of
risks.
d.
Reduce the number of work accidents in the
production process.
e.
Achieve zero accident.
2. Stakeholder Identification
Stakeholder
identification is the process of identifying people, groups, or organizations
that have an interest or impact in a decision. The company already has a
special organizational structure related to ISO, so these stakeholders are
taken from the organizational structure, such as Top Management, Ka. Internal
Auditor Team, ISO Secretary, and Head of Production.
3. Trigger Event
Trigger
event is a trigger that can trigger the occurrence of a process or activity
(event). The trigger in the design of this hazard identification, risk
assessment and control procedure are when the scheduling of the hazard
identification, risk assessment and control process begins. The process of
identifying hazards, assessing risks, and controlling the risks can be done
every six months. The goal is to make the process more controlled.
4. Determining Inputs and Outputs
In the process of
designing procedures, inputs and outputs are required. Input is used to
determine what is needed during the design process for procedures, while output
is used because of input processing. Thus, it is hoped that the output that
comes out is in accordance with the expectations of stakeholders. The following
are the inputs and ouputs expected
in the procedure design process:
Table
3
Inputs
and Outputs
|
Input |
Ouput |
|
1.
Work
accident data 2.
List
of activities during the production process 3.
Company
organizational structure 4.
List
of production support facilities 5.
List
of raw materials used in the production process 6.
Work
map (process flow map) 7.
Staff |
1.
List
of risks or potential hazards and their classification 2.
Risk
rating or assessment of each risk 3.
Control
of existing risks |
5. Determining the Process Sequence
Determining
the sequence of processes is an important part of the procedure design process
because the procedure document will later become a work guide that must be
carried out by several parties, so that in carrying out the stages the process
must be sequenced first. In determining the sequence of activities in the SOP,
it is based on a combination of methods for hazard identification, risk
assessment, and control, namely the FMEA (Failure Mode and Effect Analysis) and
FTA (Fault Tree Analysis) methods. The following is the sequence of processes
in hazard identification, risk assessment, and control in the production
process:
a. Planning a program of hazard identification, risk
assessment, and control in the production process
b. Identifying hazards in the production process
c. Conduct a risk assessment in the production process
d. Review the hazard with the highest RPN rating
e. Implement risk treatment in the production process
f. Documenting the results of hazard identification, risk
assessment, and control
g. Performance monitoring and measurement
h. Evaluate the performance of the hazard identification,
risk assessment, and control process
i.
Implement
a routine OHS socialisation program every 6 months
6. Determining Key Performance Indicator (KPI)
Key
Performance Indicator (KPI) is a measurement used to assess the quality or
performance of an existing process. The indicator in this KPI measurement is
the decrease in the number of work accidents in the following year. The
following is the KPI calculation formula:
7. Define PIC
In
determining the PIC needed in the process, the flowchart used is a cross
functional flowchart. Cross functional flowchart can represent the interaction
of actors with existing process activities.
8. Define Authority and Responsibility
To clarify each
person's duties and facilitate the making of appropriate policies based on the
results of job evaluation, each PIC must define his or her responsibilities and
authorities.
The
sequence of activities in the Risk Control SOP is based on the PDCA cycle. The
activities in the SOP are made following the PDCA cycle so that the activities
made can control a problem in a coherent and structured manner. In addition, in
PDCA there is Plan-Do-Check-Act,
where the stages form an unbroken cycle, so that the activity/process can be
improved continuously.
Based on the design results above, the next step is to verify the results of the design of hazard identification, risk assessment and control procedures. This verification process is carried out based on references and references related to the selected problem-solving method or with requirements used to solve existing problems. In addition, in the verification process, it is checked whether the design proposal that has been made is in accordance with the method/framework/model. The following is a verification of the design results that have been made:
Table
4
Verification
of Design Results
|
Plan Results |
Requirement |
||||
|
ISO
45001:2018 |
PP No. 50 of
2012 |
PDCA |
FMEA |
FTA |
|
|
SOP for Risk Control: a. Risk Control Plan Form b. Hazard Identification Form c. Risk Assessment Form d. List Risk Treatment Form e. Fault Tree Analysis (Fault Tree) Form f. Criteria Severity, Occurrence, and Detectability |
Fulfilled |
Fulfilled |
Fulfilled |
Fulfilled |
Fulfilled |
The next stage after the verification process is the process of validating the results of the draft procedure for hazard identification, risk assessment and control. At this validation stage is a description of the feedback from stakeholder related to the results of the design that has been made. The following is a validation of the design results:
Table
5
Validation
of Design Results
|
Validation Category |
Validation Targets |
Fulfillment |
|
Performance Targets |
The results of the design can be understood by users. |
The design results are made using language that is easy for users to understand and has clear steps. |
|
The results of the design can be used to determine the hazards or risks that occur in the production process. |
The design results have activities to identify hazards or risks that occur in the production process. |
|
|
The results of the design can be used to determine the level of risk based on the risk assessment that has been carried out in the production process. |
The design results have a rating scale severity, occurrence, and detectability to assess the risks that occur and determine the level of each risk. |
|
|
The results of the design can be used to find out what actions need to be taken to control risks in the production process. |
The design result has a list risk treatment that can be used to control risks in the production process. |
|
|
The results of the design can reduce the risk of work accidents in the production process. |
The design results have structured activities to identify, assess, and control the risks that occur in the production process. |
|
|
Stakeholder Requirement |
The design results can help companies to achieve zero accident. |
The results of the design have implementation activities risk treatment. |
The next stage after verifying and validating is to analyze the results of the design that has been made. At this stage, the researchers analyzed the results of the draft SOP for Hazard Identification, Risk Assessment and Control based on the company's existing conditions and analyzed the strengths and weaknesses of the SOP for Hazard Identification, Risk Assessment and Control.
SOPs for Hazard Identification, Risk Assessment and Control are made based on the company's existing conditions, where in the implementation of OHS in the company there is no process to identify hazards, assess risks, and control risks. The following are the differences between the company's existing conditions and the proposals that have been made:
Table
6
SOP
Risk Control Analysis
|
No. |
SOP name |
Difference |
|
|
Existing |
Proposal |
||
|
1. |
Risk Control SOP |
The company does not yet have an SOP for hazard identification, risk assessment and control in the production process |
The company has SOPs for identifying hazards, assessing risks, and controlling them in the production process |
Before the company had procedures for identifying hazards, risk assessment and controlling the production process, the company made efforts to improve and control OHS by facilitating its workers with PPE in the production process. Even so, workers still do not comply with the rules for using PPE on the grounds that when using PPE their body temperature will increase. This made the company make another policy related to OHS, namely providing reward for workers using PPE and punishment in the form of fines for workers who do not use PPE. However, with its reward and punishment still makes workers disobey the rules for using PPE in the production process. Thus, in the production process there are still work accident rates.
This SOP draft proposal was made to comply with ISO 45001:2018 Clause 6.1 and PP No. 50 of 2012 which states that companies must develop an OSH plan to reduce work accidents through hazard identification, risk assessment, and control. Thus, the existence of SOPs for Hazard Identification, Risk Assessment and Control can assist companies in identifying hazards that occur in the production process, assessing existing risks, and making controls over these risks.
After further analysis based on the data processing stage up to the verification stage of the design results, the SOP for Hazard Identification, Risk Assessment and Control is in addition to fulfilling the requirements in ISO 45001:2018 Clause 6.1 and PP No. 50 of 2012, the SOP has also been verified as complying with several other clauses as a support for clause 6.1.
1) ISO 45001:2018 Clause 2 with Article 5 PP No. 50 of 2012
From the second integration requirements Based on these results, the results obtained stated that companies are required to implement OHSMS. Based on this, clause 2 with Article 5 can be stated as requirements additional in the Risk Control SOP because the existence of the SOP can fulfill requirement from clause 2 of ISO 45001:2018 with PP No. 50 of 2012 Article 5.
2) ISO 45001:2018 Clause 3 with Article 1-2 PP No. 50 of 2012
From the second integration requirement from this, the results obtained stated that the company must determine terms, definitions, and objectives related to OHSMS. The SOP for Hazard Identification, Risk Assessment and Control includes the definition and objectives related to OHS, so that it can be said that the SOP fulfills requirement clause 3 ISO 45001:2018 with PP No. 50 of 2012 Articles 1-2.
3) ISO 45001:2018 Clause 5 with Article 6 PP No. 50 of 2012
The results of the integration of the two requirement it states that top management must show leadership and commitment in establishing OHS policies, one of which is the SOP for Hazard Identification, Risk Assessment and Control. With these SOPs, top management can continue to be committed related to OHS policies.
4) ISO 45001:2018 Clause 5.3 with Article 9 PP No. 50 of 2012
The results of the integration of the two requirements states that the company must determine the roles, responsibilities, and authorities of the organization. The SOP for Hazard Identification, Risk Assessment and Control has defined responsibilities and authorities to assist in the process of hazard identification, risk assessment and control.
5) ISO 45001:2018 Clause 6.1 with Article 9, 12-13 PP No. 50 of 2012
The results of the integration of the two requirements states that the company must make an OSH plan to reduce OSH accidents in the form of a process of identifying hazards, assessing, and controlling risks. Requirement this has been fulfilled by researchers by designing a proposed procedure, namely Risk Control SOP.
6) ISO 45001:2018 Clause 7.5 with Article 10 PP No. 50 of 2012
The results of the integration of the two requirements states that in making an OSH plan, support is needed in the form of resources, competence from workers, communication between organizational functions, and document documentation. In this case, the SOP made by the researcher contains document documentation activities, where these activities can fulfill clause 7.5 regarding documented information.
7) ISO 45001:2018 Clause 8.1 with Article 11 PP No. 50 of 2012
The results of the integration of the two requirements states that the company needs to make control measures based on the results of the process of identifying and assessing existing risks. In the SOP for Hazard Identification, Risk Assessment and Control, there are implementing activities risk treatment in the production process based on the results of hazard identification and risk assessment, in which of these activities there are sub-activities, namely making a list risk treatment and implement it.
8) ISO 45001:2018 Clause 9 and 9.1 with Article 14 PP No. 50 of 2012
Based on the results of the integration of the two requirements it was found that companies need to monitor, measure, and evaluate OHS performance. The SOP for Hazard Identification, Risk Assessment and Control includes monitoring activities implementation of risk treatment, after that performance measurements were carried out using Key Performance Indicators (KPI), and finally there is a performance evaluation activity from the process of identifying hazards, risk assessment, and controlling whether the objectives of the SOP have been achieved.
9) ISO 45001:2018 Clauses 10 and 10.3 with Article 15 PP No. 50 of 2012
Clause 10, 10.3 ISO 45001:2018, and Article 15 PP No. 50 of 2012 states that there is a need for continuous improvement to improve OHS performance. Therefore, the sequence of activities in the SOP that has been made is adjusted to the PDCA cycle (Plan-Do-Check-Act) so that the results of the SOP are not just activities but can continue in a cycle so that improvements can be made in its activities.
Based on the results of the activity evaluation sub-chapter and requirements implementation of OHS, in addition to the proposal in the form of procedures for identifying hazards, risk assessment, and controlling them, there are other suggestions, namely routine socialization programs related to OSH for workers and making safety sign in the production area. The two proposals were not carried out further research by researchers because the limitations in this study were design proposals made only to fulfill requirements ISO 45001:2018 Clause 6.1 and PP No. 50 of 2012. In addition, with the procedures for identifying hazards, risk assessment and control, the two proposals can be included in one of the control efforts or risk treatment which will be determined by the company.
In addition to analyzing the Risk Control SOP, researchers also need to carry out an analysis related to the strengths and weaknesses of the SOPs so that the deficiencies that have been identified can be corrected in further research.
Table
7
Advantages and Disadvantages of Planned Outcomes
|
Advantages |
Disadvantage |
|
1. The results of the draft SOP can be used as a guide in carrying out hazard identification and risk assessment. 2. The results of the SOP design can fulfill requirements Clause 6.1 ISO 45001:2018 and PP No. 50 of 2012. 3. The results of the SOP design can be easily implemented in the production process. |
1. Some of the activities in the SOP involve method stages Failure Mode Analysis Effect (FMEA) and Fault Tree Analysis (FTA), where not all stakeholders knowing the two methods, so that it will have an impact on the results of the process of hazard identification, risk assessment, and control. |
The proposed SOP design
that is in accordance with the requirements of ISO 45001: 2018 and PP No. 50
Year 2012 is the Risk Control SOP. The SOP is designed to reduce work accidents
at PT XYZ. Where in the SOP activities contain stages from the FMEA and FTA
methods that can be used to identify and assess existing risks. In addition,
the activities in the SOP are based on the PDCA cycle so that continuous
improvement can be made in each activity or process.
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