Risk Assessment Analysis on Arcdem Engineering
Engineering and Industrial Services is a company engaged in Design and Fabrication of customized products especially of which includes electrical and electronic components. It is an excellent, prestigious and highly motivated company of good quality semiconductors and services In the Industry. It was built to give full service for customer’s satisfaction, high quality of products, competitive cost and quick service delivery.
ARCADE Engineering and Industrial Services was established on the 23rd day of October 1997. It is EDIT registered with certificate no of 97078368 existing under virtue f the laws of the Philippines. The principal office and plant of ARCADE Engineering and Industrial Services Is located at Block 2 Lot 3 Jupiter SST. Del nor Subdivision Talon Slings Lass Plans City and can be contacted through their landlines, 8007130 or 801 6729, or email them at [email protected] Net. The products and services that the company provides are the following: 1.
Design and fabrication of customized products specializing in semiconductors 2. Mechanical design and fabrication of Gigs and fixtures; tool and die; tracks, work holders and clamps; compression spring; graphite pins and contact pins; production abeles, chairs, cabinets and racks 3. Fabrication of any sheet metal Like stainless steel, mild steel and black Iron 4. Automation and Industrial components of pneumatics like cylinders, valves, sensors and switches: aluminum profiles 5.
Project feasibility study/ project management 6. Reverse engineering or localization of punch and die; test sockets and conversion kits The name a few of the customers of ARCADE Engineering and Industrial Services are NSP Semiconductors Philippines, ON Semiconductor, element Technologies Inc. , Microelectronic Design Technology, Process Automation PUT. LTD. , PALL, and Electric Trading Corporation. B. Organizational Chart (Corporate-wide) II. Velveteen of Risk Management In the Company A.
How Risk Management Programs Evolved ARCADE Engineering and Industrial Services is aware that this kind of industry is characterized by complex and expensive manufacturing processes, continuous of the company that force them choose practically and wisely. Within their strategic planning, risk management is present without their notice by simply considering factors that will minimize the probability of accidents in their facility layout and design which is common to manufacturing plant with complicated and delicate recesses that consume hazardous materials.
Even by simply following government laws will lead to risk management like being considerate to the environment, the company assess the risks and effect of their actions to the condition of their surroundings that even makes finding a location for their plant site becomes critical. During the production cycle, equipment failures and breakdowns affect cycle time, product quality and in turn production cost seriously. The company imposes to maintain a relevant, efficient, effective and dynamic control of manufacturing process.
In order to that, they conduct training programs for their workers to enhance their performance level and guarantee that lesser mistakes will be made that may cause industrial disasters. ARCADE treasure their staffs and employees which encourage them to create policies and procedure that will protect the safety and welfare of their workers. Unwanted events are always unexpected like calamities, fire, explosion, and other catastrophes. The company decided to conduct drills for earthquake, fire and other disasters to prepare their employees for that instant event and lessen the casualties f the real thing happens.
First aid was also taught to the workers for temporary remedy in case of emergency. For ARCADE, risk assessment and management has been a long-standing avenue for determination of their business opportunities. They are planning to spend resources on market research and evaluation of market competitors to determine their course of investment and action. Large risks with small returns are typically avoided, and conversely situations with perceived low or risks with small returns are typically avoided, and conversely situations with received low or manageable risks and large gains are developed and added to their portfolio.
Currently, ARCADE is aware what risk management is and planning to improve and apply it for the benefit and advantages it offers. One of their future plans is to apply it in their marketing strategy. B. Personnel Involved in the Initial Phase of Risk Management Program Initial Phase of Risk Management Program includes first construction of safe facilities. The company ensures that the designed facilities are safe and well-constructed. They ensure that facilities and equipment are maintained in a safe operating condition ND eliminate facility, public works and contract-related injuries and illnesses.
Personnel involved in this face include the Project Manager, Process Engineer and the Architect, which is also the General Manager himself, Architect Demerit Z. Dijon Second phase is the safety policies and procedures, they establish safety policies and procedures. Aside from training and orientation among employees, and they provide information on safety written in their policies and rules. By doing so, it is a their safety and health. The responsible for this phase is their executive secretary on he direct orders from the general manager.
Third phase is Personnel training, they provide a full range of outreach and trainings in safety and health, and they familiarize themselves with the hazards in their areas. It involves the supervisor of the plant operations since he’s the one who is knowledgeable on the operations and that he ensures that all the workers are knowledgeable on the risk on the company and provide them trainings. Last phase is Disaster Drills, this drill is for exercise in which their people simulate the circumstances of a disaster so that they have an opportunity to practice heir responses.
Their drills are used to identify weak points in a disaster response plan, and to get their people familiar with the steps they need to take so that their response in a disaster will be automatic. They perform drills tallest once a year, during the disaster drill, their people are expected to practice things like evacuating the building and assisting each other so that they will know what to do when a real alarm sounds. The personnel who plan this are the supervisor and the executive secretary with the help of the Lass Pains Fire Department.
C. Risk Management Activities Risk management is the identification, assessment, and parameterization of risks followed by coordinated and economical application of resources to minimize, monitor, and control the probability and/or impact of unfortunate events or to maximize the realization of opportunities. The company has several activities to prevent risk which includes personnel training, they are educated with the hazards associated with their workplace, as well as the actions to take in case of emergencies.
Chemical Safety Assessment, they must be assessed as to their potential severity of impact (generally negative impact, such as damage or loss) and to the probability of occurrence. Disaster Drills, they perform drills to expose their people with the steps they need to take when certain disaster occurs. Personal Protective Equipment, this includes the use of personal protective equipment to protect the employee from the chemical and physical agents in the fabrication environment.
Safe Facility Design, the personnel responsible for this designed the facility and systems that either prevent an incident from occurring or minimize the damage should an incident occur. Safety Policies and Procedures, these sets of rules and policies state some safety precautions to prevent injury at work. These activities can minimize the risks associated with environmental, health and safety hazards at the company. The aim is to ensure that no one is injured or hurt by a hazard at work. Ill.
Risk Management Program The company deploys no formal risk management programs, and there are no risk management tools being utilized. However, during the interview, it was determined that the company implements several risk prevention, reduction and treatment measures. Safe facility design and construction The company implements measures that focused on the prevention of hazardous production material accidents and fires. There are administrative controls, engineering controls, and emergency response elements. Administrative controls are procedural in nature and require that appropriate training be performed.
Examples of administrative control requirements include the following: * dissemination of semiconductor safety handbook * safety handbooks are available at the main office of the company. * The workers hired are oriented and the key factors are being discussed to newly hired employees storage plans/hazardous materials inventory statements and separation of incompatible materials, * raw materials in fabrication of semiconductors are placed in different storage areas depending if the materials are incompatible with each other that may cause combustion * placards and labeling. Warning signs like no smoking and restricted areas are posted in such a way that can be easily seen by the workers. Engineering controls are designed into the structure of the facility or include systems that either prevent an incident from occurring or minimize the damage should an incident occur.
Examples of engineering control requirements include the following: * fire protection systems, * the fire protection systems are fire drills that are being conducted and the availability of fire extinguishers and sprinklers * ventilation and treatment systems, * the ventilation systems are the exhaust fans located at each wall of every area * detection and shut-off controls, * detection and shut off controls are provided by having an emergency stop button and the circuit breaker which can be easily turned off whenever an emergency occurs * use of non-combustible or fire-resistant materials of a material that will not ignite, burn, support combustion, or construction. Lease flammable vapors when subject to fire or heat, in the form in which it is used and under conditions anticipated; any material that passes ASTM Test Method IEEE is considered non-combustible. By using adobe, brick, concrete, gypsum block, hollow concrete block, stone, tile, or similar materials for their exterior wall to prevent fire. Emergency response controls are intended to respond rapidly to, and control an fail. Emergency response controls in the company include the following: * fire access and water supply fire access and water supply are the fire extinguishers and the sprinklers. The fire extinguishers are placed in areas near the machines which are the ones prone to fire. The sprinkler turns on whenever a smoke has been detected. Emergency alarms and emergency control stations * an emergency alarm is placed in one wall near the fabrication are which can be easily pulled once an emergency occurs * emergency response equipment, and * a first aid kit including a burn kit is located near the fire extinguishers and inside the comfort room for easy access in case of emergency. * spill control, drainage and containment. Spill kit containing absorbent, pads and waste bags are available for easy management of unexpected leakage. Personal Protective Equipment (PEP) The extensive use of personal protective equipment protects the fabrication employee from the chemical and physical agents in the fabrication environment. Another reason is to isolate the worker from the wafer for process cleanliness reasons.
Some of these equipment are the following: * Safety shoes * Goggles * Chemical protective gloves * Respiratory protection * Flame-retardant coveralls in all areas of the facility where there is potential for fires * Emergency escape respirators The aforementioned equipment are all provided by the company. Since the company only hires contractual whenever demand is high, there is fluctuation of employees. These equipment are not given to the employees but are assigned to them and will only be used whenever needed. Disaster Drills While a disaster drill may not anticipate every potential scenario, it gives people an idea of how to behave during a disaster. The following are the disaster drills being implemented by the company: 1. Fire Drill.
Training includes: who and where to call, how to check the batteries in the smoke detectors, how to use a fire extinguisher, owe to warn everyone about a fire, how to escape from the house if it is on fire, where to meet after escaping, common sense rules about when to try to extinguish a fire and when to Just leave. Fire drills are done annually during the month of March since it is fire prevention month. The company collaborates with the Lass Pains Fire Department in conducting fire drills. 2. First Aid Drill. Training includes: where the first aid kit is located, what is in the first aid kit and how to use each item, and basic first aid skills.
First aid drills are held twice a year every June and December. The schedule of the first aid drill is planned by the executive secretary on the direct orders of the General Manager. Disaster kit, which vehicle will be used for evacuation, how to quickly access each person’s disaster kit and put it in the vehicle, what other items should be taken when evacuating and how to get them quickly. Emergency evacuation drill is done annually during the month of August. This is five months after the fire drill as to give time for planning for the supervisor and the executive secretary. 4. Natural Disaster Drill. Training includes: what specific steps to take during a flood, earthquake, tornado, etc. At steps to take during the actual event, and what steps to take after the event (turning off the power/water/natural gas). Natural Disaster Drill is not done annually. According to Ms. Freshened, this is only done when the General Manager has instructed to do this. Personnel Training Personnel are trained on the use of the protective clothing and emergency response controls. They are educated with the hazards associated with the physical and chemical agents, as well as the actions to take in case of emergencies through drills. There is also specialized on-site emergency response teams that will take immediate action during exposure to hazards.
Personnel Training are involves the supervisor of the plant operations since he’s the one who is knowledgeable on the operations and that he ensures that all the workers are knowledgeable on the risk on the company and provide them trainings. Chemical Safety Assessment The company’s chemical safety assessment required the assistance of an outside party. Exposure scenarios were performed, forming the foundation of chemical safety assessments. An exposure estimation and risk characterization table has been attached to each exposure scenario document in order to provide scientific aground of the assumptions. All the chemicals used by the company are listed in the Philippine Inventory of Chemicals Chemical Substances (EPICS) and was assessed under the Environment Management Bureau to authenticate that will not violate Philippine Environmental Laws.
It is mandatory that the company must submit annual reports regarding the chemicals and substances they used in their production to monitor its impact to the environment and to the internal and external individuals who might be affected. Annually, the company is hiring a professional in handling and measuring the Heimlich they used like a Chemical Analyst, Chemical Engineers, etc. In order to guide them in the assessment of the substances used in the production and in construction of reports. The following criteria were considered in the chemical safety assessment (refer to forms below). The exposure scenario is a system of conditions that describes that how a given avoid or reduce the human and environmental exposure.
The exposure scenario contains the appropriate risk assessment measures and operational conditions which ensure that all the risks arising from the use of the substance can be controlled appropriately. Based on the risk characterization for human health and environment in the sample completed exposure scenarios, the risks are controlled adequately for the sample substance. Failure Detection Although the company keeps no records of the details of the failures occurring in their products, they follow a process in the detection of failures in a manner shown below: Preservation of Failed Devices For failures resulting from mechanical damage or environmental corrosion, the original condition of the device must be maintained by taking photos.
To avoid progress of failure, the sample should be handled and stored with great care so that he environmental (by temperature and humidity), electrical, and mechanical damages to the device are prevented. Mounting Gigs and fixtures can be useful for handling small devices. Visual Inspection Visually inspecting the external condition of the device often provides valuable information for subsequent analysis. First the device is inspected by eyes to check for any differences from good ones. Then microscopic inspections are carried out for detailed observation. A stereoscope’s with magnifying power 4 to 80 is used. Illumination from various angles is used to obtain the best view of the sample. A jugular microscope with higher magnification power (50 to 2,000) is sometimes used to search for failure spots.
If further observation is required to detect package cracks, surface wear, particles, whiskers, disconsolation, or migration, a scanning electron microscope (SEEM) is used. If elemental analysis is required and a sufficient amount of sample is available, atomic absorption photometry is performed. If the failure is limited in a very small area and it is difficult to obtain the substance in question, electron probe micro analysis (EMMA) should be used. The following items should be observed in visual inspection. 1) Dust The presence of metal, metal oxide, or ash indicates the device has been used in a severe environment such as at a steel mill or power plant. This can be one of the causes of characteristic deterioration. 2) Contamination Small remaining traces of water, oils, solder flux, or spray liquids (e. G. Insulating (3) Lead Disconsolation The leaders are usually plated to improve solidarity and resistance to corrosion. Plating disconsolation often indicates oxidation by heat, acculturation, flaws in the base material, incomplete preprocessing, or defective plating. (4) Lead Cracking by Stress Corrosion If Cue-Zen alloy and many other copper-based alloys under external stress or internal residual stress are exposed to ammonia, amines, moist air, and/or high temperature environment, stress corrosion can occur. It is diagnosed by observing the morphology of the cracks and feature of the grain boundary using an SEEM. 5) Mechanical Lead Damage This damage mode depends on the external form of the lead, load, and the environment. Major breaking types are fatigue breakage, shock breakage, and creep breakage. The fatigue breakage is caused by repeated stress and the creep breakage by stress applied over a long period of time. Other breakage includes brittle fractures and elongation breaks. The brittle fractures involve rapid formation of a break without plastic deformation. The elongation breaks develop gradually following plastic deformation. It is important to carefully examine how the breakage occurred to determine the type of breakage. The cracked surface or the surface of broken ends sometimes exhibits a wave pattern, which indicates mechanical fatigue.
A disk or ratchet-shaped pattern implies a stress concentration at this point. (6) Package Cracking Cracks are the cause of leakage of moisture into the device. Glass cracks in the hermetic seal are easy to overlook. Inspection using penetrate dyes is effective for small cracks. (7) Metallic Migration When an electric field is applied at high temperature and high humidity, metallic ions in the insulation material or at its surface migrate from the positive terminal to the negative, where they are reduced and deposited. This can ultimately lead to a short circuit between two terminals. A metrological and electron probe micro analysis (EMMA) are used to observe this phenomenon. 8) Whisker In most cases, solder plating is applied to the lead pins. Accordingly, there is a possibility of tin whiskers being generated regardless of whether the solder is eutectic or lead-free. The generation of whiskers from conventional eutectic solder plating can be suppressed by adding lead. However, lead-free solder plating must be monitored for whisker generation by using, for example, SEEM. When one or more defects indicated above are detected, the operator or quality location of failed point, physical analysis of chip, or estimation of failure mechanism, whatever category the failures fall under. All these actions eventually lead to the corrective action. ‘V.
Problems in Implementing Risk Management Programs The major problem that had arisen during the implementation of the informal risk management programs identified earlier is concerned with the financial aspect. Aside from the facilities and equipment that are vital for the prevention of environmental, health, and safety hazards, the company was also obliged to hire additional personnel for emergency response teams and trainings. For the chemical assessment of the substances used in the company, it also became imperative that the company seek assistance from an expert in assessment of chemical, which also entailed additional costs. Another concern is the resistance of some employees to changes, specifically those resulting from the chemical safety assessment.
Some employees have low adaptation skills and were not willing to participate in trainings for safety. Moreover, even with the aforementioned risk management programs being implemented, accidents are still inevitable, although the impacts are not as severe as those which occurred before the programs were being carried out. V. Solutions Undertaken to Resolve Problems On the account of the problems identified above, the company modified their manufacturing processes to improve yields and product performance and decrease costs. Hence, the company was able to allocate funds that are intended to support the present risk management programs and make the adoption of future improved risk management programs possible.
Communication barriers between the management and the employees were also eliminated, as this was identified to be the cause of the employees’ resistance to changes. Before improvements and modifications in the manufacturing processes are introduced, it was first made sure that the employees completely understand why he program is being implemented, and it should be made known to them that these changes will also benefit them in one way or another. VI. Future Directions of the Risk Management Program The company, being a semiconductor company, is subjected to fast-paced technologies in new product innovations and high competitiveness in the industry.
To keep in pace with the rapid changes in technology, the company might need to modify some of its manufacturing processes, which would require new risk management programs. New manufacturing equipment may be introduced, which nowadays are geared towards nature conservation and hazard reduction. Hence, this implies that operational risks may be much easier to manage in the future, and the company can direct its attention to other aspects worthy of consideration such as financial risks, since cases of budget shortage for operational risk management programs were reported to occur when these programs were first introduced. According to the Ms. Freshened, the company has no future plans on formalizing the risk management program that the company is already using.
Due to problems in financial matters and the resistance of the employees to change, the risk management that they are already practicing is already enough for them as of now. VI’. Conclusion The company, although it doesn’t have formal risk management programs, has a strong foundation in risk prevention since it started with the construction of safe facilities. If adequate engineering design and risk management systems are not implemented in the course of facilities installation, future investments in increasingly complex and expensive facilities are at great risk. The result is a greatly reduced risk of catastrophic losses and threats to personnel and the environment.
The company’s administrative controls, engineering controls, and emergency response elements provide many benefits. First, all of the causes of fire and fluid leakage losses are detectable and preventable using these measures. Employees are also ready in case of emergencies, along with the help of the Lass Pains Fire Department who were trained specially for accidents and disasters. Moreover, the company’s involvement in chemical safety assessment activities has a positive impact in its corporate social responsibility since this ensures that the manufacturing processes of the firm has no adverse effect to the environment, which will also benefit the people.
Considering that the company no formal risk management programs yet, and they jack in the documentation since they keep no records of casualties and accidents, then there is still a big room for improvement. VIII. Recommendations During the interview with Ms. Carmen R. Freshened, several problems not addressed by their informal risk management programs were identified. These were the following: * Employee absences * Economic risks * Process in fabrication of semiconductors To address these problems, it is highly suggested that the company establish a risk management team, so that formal risk management programs will commence. With the team, problems and room for improvements will be easily identified using
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