INTRODUCTION

the industries of developing countries like Pakistan results in enormous human cost and
devastating effects on the economic potential and the productivity of industry and country
also. The top management of industries should be conscious regarding the Occupational
Health and Safety along with the production pressure. Safe working environment of any
industry is beneficial for both the direct and indirect beneficiaries. Direct beneficiaries
include workers and firm or industry. The save workplace environment is of great importance
to firm or industry, the firm can compensate its losses and hence can improve the
productivity. The indirect beneficiaries which also receives benefits from the save workplace
environment of the industry include consumers, contractors, and the families of the workers.
The Managers and the policy makers are the key here for the development of the policies
regarding the Occupational Health and Safety. They must design policies on the basis of
proactive approach. The Health and Safety related accidents are not only responsible for
financial loss, but they also result in the reduction of the quality and the quantity of the
manufactured products.
The Unsafe and Unsatisfactory workplace conditions result in the crumbling of the
confidence level of the workers. Due to this unsatisfaction, the workers quit the firm or
industry and the industry faces the shortage of the highly skilled and technical labor. Mostly
it becomes impossible for the firm to recruit the new skilled labor over the very short notice
which affects the operations and productivity of the industry to great extent. Furthermore, the
increased health and safety related accidents in any industry results in the negative
impression on the reputation of the industry as well. No wants to work in the industry to be
get injured or killed. The degradation of the industry’s reputation results in the poor public
relations of the industry. The large number of the health and safety related accidents in any
firm or industry can also results in the delay of the orders from the customers. So, the factory
or the firm loses its trust among the customers and eventually loses its market
competitiveness. In other words, if the firm fails to devise the policies regarding the
Occupational Health and Safety of its workers, the firm cannot survive in the market.

Objective
The main objective of this report is to identify and critically analyze the Occupational health
and safety related hazards and risks to which the workers of the Railways Carriage Factory,
Islamabad is exposed to and to provide the necessary recommendations in form of a health
and safety plan to avert the risks and hazards which have potential to impart serious
accidents.
PAKISTAN RAILWAYS CARRIAGE FACTORY, ISLAMABAD
Pakistan Railway Carriage Factory, Islamabad was set up with the collaboration of a
Germany in 1970 for manufacturing of the passenger carriages. Different spare parts of
locomotives are also manufactured. And the maintenance of locomotives is also carried out to
some extent. The rehabilitation and repair of the damaged and defective railway coaches are
also carried out in Railway Carriage Factory. The factory has a total area of 58 Acres and 13
Acres of area covered. The factory has the manufacturing capacity up to 150 passenger
coaches annually if the factory is run on single shift basis. However, the manufacturing
capacity can be elevated with the aid of double shift.
HAZARD IDENTIFICATION AND ASSESMENT
Hazard Identification and assessment is basically a process of identifying the hazards which
have potential to cause serious accidents, injuries and illnesses and evaluating the risks
associated with the identified hazards and management of the risk of the hazards by
incorporating the hazard controls.

Significance and Methodology

The failure of the identification and assessment of the present hazards is the root cause of the
health and safety related workplace accidents, injuries and even causalities. The effective and
efficient health and safety policies are the one which are based on proactive approach towards
the identification and assessment of the present hazards which could result in serious
accidents and injuries. The following are the steps which should be taken for the
identification and the assessment of the present hazards in the workplace:
1. Collection of the existing information regarding workplace hazards
The information related to the present hazards in the workplace to which the workers are
exposed is obtained through the collection, organization, and the exchange of the information
with the workers. The information which is available in any firm’s workplace consists of:
 The operating manuals of machinery and equipment present in industry’s workplace.
 The data sheets provided for the safety instructions by the manufacturers of the
chemicals.
 Previously available record (pattern) of accidents, illnesses, and injuries.
 Existing Health and Safety program i.e., the process safety management and the
available personal protective equipment of the workers.
 The participation and interest of the workers in the health and safety related
awareness programs.
 Inspection reports of the previous inspections of the consultants or government
agencies.
2. Workplace Inspection for Safety Hazards
There are chances of introduction of the hazard in the workplace with the passage of time due
to the change in the manufacturing processes and the tool wear and the flaws arising in the
machinery due to the negligence in the maintenance and poor housekeeping practices. So, the
inspections are necessary so that the errors can be identified prior to it becomes a cause of
serious accident.
 The regular inspection of the workplace is made in which equipment, operations and
the facilities provided to the workers are monitored critically and the response of the
workers is also recorded that how they address the hazards to which they are
exposed.
 The results of the inspection are documented which can also be in form of photos or
videos so that the correction of those hazardous aspects could be made possible and
get verified weather it has been addressed or not.
 The regular inspection of the industrial transport vehicles is also made which
includes fork lifters, heavy dumpers, trucks, and overhead cranes.
 Inspection of workplace is done to check for the potential of the following hazard in
any industry:
 Housekeeping Hazards.
 Hazards related to fall, trip, and slip.
 Electricity Hazards.
 Operational Hazard related to machinery.
 Hazards resulting from the poor maintenance of equipment.
 Fire Hazards.
 Hazards due to poor work practices.
 Ergonomic Problems.
 Shortage of the emergency equipment and procedures.
 Before the introduction of the new equipment, operations and workplace layout, the
necessary training and the awareness regarding the new equipment and the operations
must be provided prior to exerting the industrial pressure on the workers. So, that the
hazard potential due to the introduction of the change in the machinery and processes
must be eliminated.
3. Identification of the Health Hazards
The identification of the hazards related to the health of the workers is far more
difficult as compared to the physical hazards because the factors which are
responsible for the health hazards are often invisible, unnoticeable, or even odorless
and have potential to impart serious health illnesses to the workers e.g., vapors of
poisonous gases. The following are some health hazards present in any manufacturing
industry:
 Chemical Hazards resulting from the exposure of the workers to the
adhesives, toxic powered chemicals, chemical solvents, dyes, and paints.
 Physical Hazards resulting from the exposure of the workers to excessive
sound above the safe audible level, radioactive radiations, and high
intensity heat.
 Biological Hazards resulting from the exposure of the workers to the
pathogens which can cause infectious disease in the workers e.g., Food
borne diseases due to the availably of the outdated and the food prepared
in poor hygienic conditions within the industry premises.
 Ergonomic Hazards resulting from the lifting of the heavy loads, repeated
motions and the immense vibrations which could result in the muscular and
skeletal injuries among the workers.
 Medical history of the workers suffering from the different diseases should
also be taken into account to minimize the health-related hazards.
4. Conduction of the investigations of the incidents
The conduction of the investigation of the accidents, injuries and the illnesses provide
the clear picture of the root cause responsible for incidents so that the cause could be
 addressed to eradicate the cause of that hazard to prevent the further accidents,
injuries, and illnesses.
5. Identification of the Hazards associated with the Emergency Situations.
There are also certain foreseeable scenarios and situations which are also hazardous
and can cause serious accidents. These Emergencies related hazards must also be
identified, and health and safety policies must be devised by keeping in account these
hazards. Few emergency related hazards are listed below:
 Explosions and fires.
 Release of Poisonous Chemicals.
 Spillage of Hazardous substances.
 Unplanned shutdown of machinery and unusual maintenance operations.
 Natural Disasters.
 Structural Collapse of Building or Heavy Equipment.

IDENTIFICATION AND ASSESMENT OF HAZARDS AT

RAILWAYS CARRIAGE FACTORY ISLAMABAD
Purpose
The purpose of Identification and Assessment of the Hazards of the Railways
Carriage Factory Islamabad is to deliver the Factory management and workers the
necessary guidance regarding the management of the risk of the serious injuries,
illnesses and the damage to the property and money associated with the Identified
Hazards.

Identified Hazards and associated Risks.

The following are the identified hazards and their associated risks:
1. Hazards related to the machinery and operations.
There is availability of wide range of heavy machinery at Carriage Factory
Islamabad including the lathe machines, sharp sheet metal cutting machines,
bending machines, forging presses, drilling machines, griding machines and
shaper machines. Many hazards are associated with working on these
machines without following standard safety practices and protocols, lack of
required personal safety equipment and lack of proper training required to
perform the operations.
Risks associated with Machinery and Operation related hazards and its
effects.
Due to the exposure of the workers to the moving, exposed, and sharp
machine components, workers are at risk of injuries such as cutting and
crushing of body parts or even death due to entanglement, friction, abrasion,
cutting, severing, shearing, stabbing, puncturing, impact, crushing, drawing in
or trapping etc.
2. Electricity Hazards
The hazards that have potential to cause injuries and accidents in the carriage
factory are shocks, arc flash in welding plants and fire due to the short circuits.
Risks associated with the Electricity Hazards and its effects
High voltage electricity can even cause death of the workers and we have been
informed about the various such cases.

3.

Fire Hazards
The fire hazards are also present in the carriage factory Islamabad due to the
electric short-circuits and the availability of the highly inflammable substances
and the explosive chemicals. The fire hazards are also associated with the
 welding and torch cutting forging, brazing, casting, soldering, and burning.
These all process have hazards of fire associated with them.
Risks associated with the Fire Hazards and its effects
Fire hazards can seriously cause burns, and they also have the potential to
cause the death, if fire spreads too much. Fortunately, the established safety
plans work well, there had been reported only one minor fire incident in the
factory.

4. Chemical Hazards:
The series of the chemical hazards are also observed in the factory due to the
exposure of the workers with the heavy metals, poisonous gases and the
metallic chips coming out of the machines. Furthermore, the exposure of the
workers to the adhesives, powered chemicals, poisonous dyes, and paints can
also cause serious injuries and illnesses to the workers.
Risks associated with the Chemical Hazards and its effects
The risks associated with the chemical hazards in the factory are the skin
irritation and corrosion, respiratory disorders like Emphysema and Asthma
due to the emission of the smoke from the engines of locomotives and the
exposure of the different poisonous chemical and substances. Furthermore,
these chemical substances can also cause different nervous disorders, heart
and phycological disorders as well. But the established safety plan works well
in this regard as well and there are only 1 or 2 cases reported with the injuries
and the illnesses due to the chemical hazards.

5. Biological Hazards
The biological hazards present in the factory were due to the exposure of the
workers to the microorganisms like bacteria, fungi and viruses which are
harmful to the health of the workers. The biological hazards are present in the
 factory due to the large number of the workers working in the congested space
having poor ventilation, the availability of the drinking water contaminated
with the pathogens to the workers and the availability of the food
contaminated with the pathogens in the factory’s canteen or mess.
Risks associated with the Biological Hazards and its effects
The risks associated with the biological hazards are infections, allergies, and
poisoning. The risks associated with the biological hazards are the air borne
diseases due to poor ventilation system, water borne diseases due to the un
pure drinking water and the food borne diseases due to the consumption of the
contaminated food. A few such cases are observed in the factory due to the
flaws in the established safety plan in addressing the biological hazards.

6. High Noise Hazards

The high noise hazards are also present in the carriage factory due the
operational heavy machinery, locomotive engines, operational overhead
cranes, hydraulics, and pneumatics forging presses, manual hammering, and
fitting operations.
Risks associated with the High Noise Hazards and its effects
The high noise level above the safe audible range due the locomotive engine
testing, operational heavy machinery and overhead cranes imparts risks of the
loss of the hearing, hypertension, and psychological disorders among the
workers of the factory. A few cases are also repeated in the factory.
7. Slips, trips and falls Hazards
Due to the oily, slippery, and messy floors and walkways due to the squirted
lubrication and fuel oil from the heavy machinery and locomotive engines in
the carriage factory, the hazards of falling on floor, or moving exposed
machine parts (sharp and entrapping) is also present in the factory.
Risks associated with the Slips, trips and falls Hazards and its effects
Oily walkways can cause slips and falls due to which the serious muscular,
skeletal, neurological injuries can occurs. Even cutting, crushing and deaths
can also happen due to slippery walkways. 1 such case is also reported over a
last couple of years in the railway carriage factory.

8. Overhead Cranes and suspended heavy loads

Overhead cranes are extensively used in the carriage factory to transport the
machinery to one operational unit to other. The hazards associated with the
overhead cranes is the falling over of the carne or the suspended load or
component from the carne.
Risks associated with the Operational Overhead Cranes and its effects
The falling over of the overhead cranes or heaving suspected loads can cause
serious neurological injuries or even death of the workers. 1 such accident is
reported which resulted in the severe damage in form of lives of workers and
the damage to the building as well.
.
 9. Ergonomic Hazards
In Factory the workers are also supposed to lift heavy metallic objects and
sheets manually due to which the stresses act at the bodies of the workers at
the different postures.
Risks associated with the Ergonomic Hazards and its effects
Due to the ergonomic hazard, there are risks that the workers might develop
the musculoskeletal disorders. But fortunately, there is no such injury reported
yet in the carriage factory.

GENERAL CONDITIONS LEADING TO SAFETY

THREATS IN THE CARRIAGE FACTORY
 There were almost no safety instructions and hazard notions which were displayed
on walls and on machinery.
 The workers were carrying out their tasks with very poor safety measures.
 There was not even a single fire extinguisher at the workplace to addresses any
emergency situation. According to the factory manager the fire extinguishers were
present in the storeroom but were not at workplace.
 No proper Emergency Exit was demarcated, and emergency procedure was not
defined. The emergency alarms were present, but their functionality could not be
predicted.
 Mostly, the workers in the carriage factory were working without any personal
protective equipment (PPE). A few workers which were working with very
hazardous processes or equipment were wearing the PPE but that was not effective
and was very old and defective. According to the factory management they were
running out of the funds allocated for the purchasing of the PPE.
 There was first aid box present in the work area, but that first aid box did not
contain the necessary objects. There was no Medical Officer or Doctor available
which could provide the necessary first aid to the injured workers.
 All the dangerous machines were without the guards and the safety devices and
the moving machine parts were exposed to the workers.
 Heating equipment have no cooling fans.
 Overall, there was the display of the poor Housekeeping and Layout by the factory.
No one was conscious about health and hygienic conditions at the factory. There
were different waste metal parts, tools, metal chips and oil all over the floor and
the walkways were not free to move.
 There was also negligence and the overconfidence on part of the workers due to the
illiteracy, arrogance and the lack of the training and the awareness about health
and safety principles.