SCENARIO Cloudline Windows is a manufacturing organisation that produces bespoke windows. It has been in operation for 50 years. The organisation employs 100 production workers and 12 office workers. There are two production shifts each day from Monday to Friday.
The window factory consists of four departments in the main warehouse: goods-in, extrusion, fabrication, and assembly. Within the assembly department, there is a small quality control (QC) area, where windows are inspected for defects and tested to confirm that they meet the quality standards. There is a despatch area where finished goods are temporarily stored before being distributed around the country. The glass used in the windows is manufactured at a different location and brought to the goods-in department. The factory is managed by the managing director (MD). There is also a fabrication manager (FM) and an assembly manager (AM) who oversee specific departments. There are plastic strip curtains between the car park and the QC area. Previously, there were also strip curtains leading to an outdoor area, where the delivery vehicles are parked, however these were torn and blown away in strong winds.
The offices are located in an adjacent building near to the assembly department. In this building, there is also a training room and break room for all the workers. This building is older than the rest of the factory and was built around 1960. The office workers work closely with the goods-in workers and frequently visit goods-in to check stock levels. There is a car park located directly next to the offices.
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The window frames are made entirely at this factory. Most window frames are made of uPVC (unplasticised polyvinyl chloride) plastic. In the extrusion department, the uPVC pellets are forced through a die to create the lengths of uPVC material for the window frames. In the fabrication department, the window frames are made from the uPVC lengths, that are cut to the required size and heat-fused together into frames. The frames are then brought together with the window glass on the two assembly lines, where the window accessories (hinges, window handles, and locks) are also added.
New venture to make metal-framed windows Changes in architectural design and style means that more customers are asking for metal-framed windows instead of uPVC. Cloudline Windows has set up a small-scale aluminium-frame welding department in one part of the fabrication department. The FM is very keen to make this new venture a success, as they believe that this will be a way that the organisation can expand its business.
Cloudline Windows currently buys lengths of aluminium in the required size to make the frames. At the factory, this is cut to size and mitred (two ends of the material cut at angles to join together to make a 90-degree corner). To form the four corners of each frame, the mitred pieces of aluminium are welded together. This must be done using a TIG (Tungsten inert gas) welding technique. This is a precise welding technique used to create a high-quality weld on metal. Only three workers are currently trained to do this; these workers spend most of their working shift, every day, welding these metal window frames. After the aluminium frame is finished, it is sent to the assembly department, and the rest of the window is made in the same way as the uPVC windows.
TIG welding the corners of the aluminium window frames produces welding fumes and ozone. Several workers have raised concerns, as they think that this new venture could have detrimental effects on their health.
There is currently no local exhaust ventilation (LEV) system in the factory, as it has never been considered necessary in the manufacture of the uPVC windows. The FM was considering whether such a system is now necessary for the welding of the metal frames. They have been reading the British Health and Safety Executive’s (HSE’s) document HSG173 Monitoring Strategies for Toxic Substances, and they decide to carry out a basic survey. They buy some colour change detection tubes from a local organisation called Quick-test Supplies Ltd and use these to measure ozone in the area close to where the workers are carrying out the TIG welding. The FM concludes from the measurements taken using the colour change detection tubes, that the exposure to ozone is generally at or below the occupational exposure limit. The FM also concludes that it is not worthwhile getting a more detailed survey carried out by a consultant.
As manufacturing the aluminium window frames is still a new venture and small-scale, the MD is reluctant to spend a lot of money installing an LEV system in this department in case the product is not profitable, and production is not continued. The MD says that the workers will have to use respiratory protective equipment (RPE) until Cloudline Windows decides whether to commit to the costs for a permanent aluminium window frame production line. If it does, this production line will have a dedicated LEV system. Therefore, the FM researches and purchases some powered respirators that can be provided as RPE for the three workers.
Extrusion department Worker X works on the extrusion line. Throughout their shift, they carry out a range of tasks; these include filling the hopper with uPVC pellets and monitoring the injection moulding machine. They also remove cut lengths of uPVC material from the cut-off saw and place these on to the storage racking near to the end of the extrusion line. Worker X moves around the extrusion line, carrying out all of these tasks. Sometimes they leave the extrusion line to take a break in the break room, or to go to the goods-in department to collect more pellets to fill the hopper. Worker X likes their job when it is busy and the extrusion line is running quickly, as it feels like the shift is over sooner. Like most of their colleagues, Worker X often wears their own headphones and listens to music while they are working, as this is a good distraction from the mundane work.
A few weeks ago, when Worker X was on shift, a noise survey was carried out by Sonu Dynamics. Worker X was annoyed that the consultant doing the survey kept watching them work and asking them questions. Worker X thought it was a waste of time as no one ever wears the hearing protection equipment (HPE). They recall that recently, the MD came straight from their office and walked around the factory floor without wearing any personal protective equipment (PPE).
Assembly department The assembly department consists of two assembly lines, line one and line two; these workbenches have roller beds that allow the windows to be more easily manoeuvred when fitting the accessories. On assembly line one, holes are drilled into the finished frames, ready for the accessories to be fitted. Since most of the windows are bespoke, the drilling is done by hand as designs can be different. The window accessories are fixed into place using a screwdriver and other non-powered hand-held tools. This intricate work requires good eyesight and attention to detail. The last stage of the assembly is to fit the window glass into the frames; this is done on assembly line two.
Workers in this department often complain about pain in their hands and wrists. They also complain about the department being cold and draughty, especially in the colder months. The lighting above assembly line one has been broken and flickering on and off for several weeks now, which is frustrating for the workers.
Worker A has been working in the assembly department for over 20 years. They find the work very boring, but they work efficiently as they like to finish on time each day; if the work is not finished, they cannot leave. Worker A knows that if they shorten or skip their breaks, they are more likely to finish work on time. Often, Worker A starts work at 07:00 and works until midday without a break. Sometimes, Worker A will offer to work a double shift, as they are saving money for a new car. These extra shifts have become more frequent as the factory has found it difficult to recruit additional workers.
Worker A starts work each day on assembly line one. Along with their colleagues, they stand at the side of the assembly line and constantly bend, twist, and reach across as they fit the accessories to the window frames. Worker A uses a rubber hammer to secure the hinges to the window, and after a few hours they feel a tingling sensation in their fingers. Unfortunately, on some days, Worker A is unable to find the best hammer as one of the other workers has taken it.
As there are many workers using the roller bed, the height cannot be adjusted. Worker A consistently finds themselves leaning over the workbench to reach the window frames. All of the workers move the window frames on the rollers as they carry out their work. This helps to minimise the need for lifting the window frames. On busy days, Worker A finds it difficult to keep up with the speed that the window frames move along the roller bed. Worker A does not want to hold up the workflow, as their colleagues will complain. As the windows are made to order, there are both quiet and busy periods. During the busy periods, all of the workers have to keep up with tight deadlines, so often find themselves rushing to complete tasks.
Usually, after their short lunch break, Worker A moves to work on assembly line two, where the glass is fitted into the frame and sealed. This work involves squeezing a sealant gun (a hand-held device used to precisely apply the sealant to the windows). This task makes the hand and wrist pain that Worker A complains about worse.
Upgrade to the IT system Cloudline Windows are in the process of upgrading their IT systems, and this requires some new cabling to be installed in the offices. The contractors carrying out the work, CableCore Solutions, are trying to minimise the disruption in the offices, where space is already limited. To install the new cabling required, they plan to remove just one of the ceiling tiles in a corner of the office and pass the cabling through it. The cabling can then be enclosed in a plastic conduit that will be screwed to the wall in several places, so that it is secure. CableCore Solutions estimate that the work will take two of their workers about two hours to complete.
Before starting the work, CableCore Solutions ask to see a copy of the asbestos register for the office building. Having consulted the register, they conclude that all of this work can proceed immediately, using methods set out in the relevant British HSE guidance HSG210 Asbestos essentials.
Supporting Documents
- The assembly department production lines
- Noise map / Floor plan
- Extract from the British HSE Noise exposure ready-reckoner (Daily exposure)
- Extracts from noise survey report from Sonu Dynamics
- Hazardous substance monitoring and control
- Extract from Asbestos Register for Cloudline Windows
Task 1: Repetitive physical activity 1
(a) What should be considered when assessing the risks to Worker A from the repetitive physical activities when working on the assembly lines? Note: Your answer must be based on the scenario and supporting documents 1 and 2 only.
(b) What control measures would further reduce risks to Worker A? Note: You should support your answer, where applicable, using relevant information from the scenario and supporting documents 1 and 2.
(20)
(16)
Task 2: Noise 2
(a) The MD has taken an average of noise levels from the noise map and determined that, during their shift, Worker X has a daily personal noise exposure of 89 dB(A) LEP,d.
They calculated it as follows (94 + 88 + 85) / 3 = 89
Explain why this approach to calculating daily personal noise exposure for Worker X is inappropriate. Note: You should support your answer, where applicable, using relevant information from the scenario and supporting document 2.
(b) A week later the MD receives the full written report of the survey from the noise consultant. Extracts from this full report are provided in supporting document 4.
(i) Demonstrate how the exposure for Worker X is between 92 and 93 dB(A) LEP,d. Notes: Your answer must be based on supporting documents 3 and 4 only.
Use calculations to support your answer.
(ii) Explain why the actual daily personal noise exposure of Worker X may be different from that stated in (b) (i). Note: You should support your answer, where applicable, using relevant information from the scenario, supporting documents 2 and 4.
(c) The MD has determined the exposure of Worker X as 89 dB(A) LEP,d but the exposure given above in (b) (i) is between 92 and 93 dB(A) LEP,d.
Explain why this difference could be significant to the health of Worker X
(d) The noise consultant makes recommendations about putting in place hearing protection zones (HPZ) and hearing protection equipment (HPE) for workers.
Explain what HPZ and HPE provisions are required in the (i) assembly department (ii) extrusion department (iii) fabrication department. Note: You should support your answer, where applicable, using relevant information from the scenario and supporting documents 2, 3 and 4.
(e) Consider the difficulties likely to be encountered when putting in place hearing protection zones and use of hearing protection equipment in this factory. Note: You should support your answer, where applicable, using relevant information from the scenario and supporting document 2.
(5)
(8)
(9)
(7)
(4) (5) (4)
(7)
Task 3: Hazardous substances and RPE 3
(a) Explain how the health of workers could be adversely affected by carrying out welding on the aluminium window frames. Note: You should support your answer, where applicable, using relevant information from the scenario.
(b) Based on the results in supporting document 5, suggest why the two conclusions drawn by the fabrication manager (FM) are incorrect. Notes: You should support your answer, where applicable, using relevant information from the scenario and supporting document 5. You do not need to provide calculations to support your answer.
(c) Based on the MD’s decision, the FM has selected a powered respirator with a helmet as the respiratory protective equipment (RPE) for the three workers carrying out the welding of the aluminium window frames.
What should the FM have considered when selecting this RPE? Note: You should support your answer, where applicable, using relevant information from the scenario and supporting document 5.
(12)
(24)
(28)
Task 4: Asbestos 4
(a) What should be considered when planning for the new IT cabling work in the office, in order to minimise the exposure to asbestos? Note: You should support your answer, where applicable, using relevant information from the scenario and supporting document 6.
(b) What control measures should be used to minimise exposure to asbestos when installing the plastic cable conduit onto the office wall? Note: You should support your answer, where applicable, using relevant information from the scenario and supporting document 6.
(11)
(15)
End of examinatio