SAFETY GOOD CATCH A LEADING INDICATOR PROMOTES PROACTIVE SAFETY CULTURE AT ASSEMBLY TEST MANUFACTURING
Authors:   Universiti Putra Malaysia, Department of Machanical and Manufacturing Engineering,
Faculty of Engineering, 43400 UPM, Serdang, Selangor Malaysia, Theng Loo Woan , Mohd Ariffin Mohd Khairol Anuar ,   Universiti Putra Malaysia, Department of Machanical and Manufacturing Engineering,
Faculty of Engineering, 43400 UPM, Serdang, Selangor Malaysia, Ismail MIS ,   Universiti Putra Malaysia, Department of Machanical and Manufacturing Engineering,
Faculty of Engineering, 43400 UPM, Serdang, Selangor Malaysia
Published: August 2024

In this project, the studies are carried out at a chipset tester assembly manufacturing with objectives of establishing a safety good catch reporting process for employee to report out any hazard, unsafety condition or unsafe act. In addition, all good catch submissions are analyzed in this study to improve the process or condition at the workplace. Throughout analyzing of all good catch submissions, pareto of hazard is identified to measure effectiveness of existing safety programs and controls. Safety good catch reporting will be served as a safety leading indicator to promote safety culture and awareness for the organization. A proposed safety good catch reporting process is benchmarked with existing quality good catch report program of the organization and DOSH JKKP 6 and JKKP 7 injury report. The proposed process is reviewed thru safety and health committee prior deployment. Later, safety good catch web tool is developed and deployed for employee to submit any safety concern and able to track and record thru the web tool in order to sustain the safety good catch program. Success of safety good catch program deployment across production is verified by safety and health committee and management. The effectiveness of program will be monitored and analyzed thru employee participation, commitment of middle level of management and engineering process owner. A series of program such as safety good catch campaign, communication have been held to promote safety good catch program to boost the employee’s participation. Moreover, safety good catch submission is further analysis and identify hazard pareto to improve the process or condition at the workplace. Then measure the effectiveness of existing safety and health programs such as ergonomic risk assessment, job hazard analysis especially when there is new product or process changed, workplace setup, preventive and maintenance task and others. Total 648 safety good catch submissions by 279 employees in this project. There are 3 main hazards identified which is physical, mechanical and ergonomics hazard. Employees who are supporting manual tasks found actively participating the program. In conclusion, safety good catch has been successfully deployed and participated by employee however two main challenges observed throughout the studies, management commitment of timely validation and engineering leadership for continuous improvement. Recommendations such as reporting of good catch submission indicator, enhancement of web tool is needed to further enhance the safety good catch program.