PROMOTIVE ACTION OF WORKER’S HEALTH, HYGIENE, AND ENVIRONMENT IN PT. GUNUNG MADU PLANTATIONS INDONESIA Extension Seminar of JICOSH Ergonomic Course Presented by : dr. Evi Maiselma
Jan 12, 2016
PROMOTIVE ACTION OF WORKER’S HEALTH,
HYGIENE, AND ENVIRONMENT
IN PT. GUNUNG MADU PLANTATIONS
INDONESIA
Extension Seminar
of JICOSH Ergonomic Course
Presented by :
dr. Evi Maiselma
PRESENTATION OUTLINE
Company Overview
Hazard Identification
Hazard Handling
Waste Management
Waste Water Treatment
Control & Monitoring
Constraint & Commitment
Summary
PT. GUNUNG MADU PLANTATIONSPT. GUNUNG MADU PLANTATIONS
Cane Plantations & Sugar FactoryCane Plantations & Sugar Factory
Lampung, IndonesiaLampung, Indonesiawww.gunungmadu.com
1975 : Established in Lampung Province
Status : Foreign Investment Company•Kuok Investment (Foreign Partner) :
45.00 %
•PT Pipit Indah (Local Partner) : 27.50 %
•PT Rejosari Bumi (Local Partner) : 27.50 %
1978 : Initial Production
Main Product : Plantation White Sugar
(Domestic Market)
Co-Product : Molasses
(Domestic & Foreign Market)
COMPANY OUTLINES
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
160,000
180,000
1978 1979 1982 1984 1985 1987 1988 1989 1991 1992 1993 1994 1996 1997 1999 2000 2001 2002 2003
Sugar (metric Ton)
PRODUCTION CHART
THE PLANT SITE
Jakarta
Tokyo
• 7,000 km from Tokyo• 400 km from Jakarta• 100 km from Provincial city
PLANTATIONS AREA
• 7 Area Divisions• 35,000 Hectares
Total Land• 25,000 Hectares
planted with cane
YearStaff &
ManagerEmployee Total
DailyWorkers
1985 120 1,640 1,760 10,000
1987 125 1,598 1,723 10,500
1989 124 1,519 1,643 8,000
1991 131 1,627 1,758 8,500
1993 133 1,723 1,856 8,500
1995 142 1,745 1,887 8,500
1997 147 1,654 1,801 7,500
1999 153 1,553 1,706 8,500
2000 153 1,526 1,679 8,500
2001 152 1,549 1,701 8,500
2002 151 1,542 1,693 8,500
2003 147 1,553 1700 8,000
EMPLOYEES & WORKERS
1%17%
82%
Manager Employee Daily Worker
EMPLOYEES & WORKERS COMPOSITION, 2003
FACILITIESRESIDENCE LOCATION
TOTALSite A I II III IV VI
Kindergarten 1 1 1 1 1 5
Elementary School
1 1 1 1 1 5
Junior School 1 1
Mosque 1 1 1 1 1 1 6
Church 1 1 1 1 4
Hospital 1 1
Policlinic 1 1 1 1 1 5
Canteen 1 1 1 1 4
Mini market 1 1 1 1 1 1 6
Club House 1 1 1 1 1 5
Foot Ball Field 1 2 1 1 1 1 7
Tennis Court 1 1 2 1 1 1 7
Volley Ball Court 2 2 4 2 2 2 14
Badminton Court 1 6 1 1 1 10
Basket Ball Court 1 1 2
Swimming Pool 1 1
SITE FACILITIES
MAIN ACTIVITIES
Cultivation
Crop Maintenance
Harvesting
Milling
Processing
Steam Generating
Laboratory
Workshop
Research
Health Service
Waste Management
Waste Water Treatment
PHYSICAL HAZARDS• Dust• Vibration• Noise• Sunburn
CHEMICAL HAZARDS• Herbicide & insecticide
application• Fertilizer application
BIOLOGICAL HAZARDS• Poisonous animal attack• Parasite infection
PSYCHO-SOCIAL HAZARDS• Overwork
Cultivation
Crop Maintenance
Harvesting
Hazard Identification
at Workplace
Plantations
Factory
Workshop
Research
Laboratory
Hospital
Plantation
SUGAR PROCESSING FLOW CHART
BAGASSE
FILTER MUD
MOLASSES
SUGAR
CURING
MASSECUITE
BOILING
SYRUP
EVAPORATION
CLEAR JUICE
CLARIFICATION
MIXED JUICE
MILLING
CANE
WATER
SO2 GAS
MILK LIME
IMBIBITION WATER
SO2 GAS
PHYSICAL HAZARDS• Dust• Ash• Noise• Vibration• Heat
CHEMICAL HAZARDS• Chemical for equipment
cleaning• Chemical for processing• Chemical for Boiler
PSYCHO-SOCIAL HAZARDS
• Overwork
Milling
Clarification
Evaporation
Hazard Identification
at Workplace
Plantation
Factory
Workshop
Research
Laboratory
Hospital
Factory
Hazard Identification
at Workplace
Plantation
Factory
Workshop
Research
Laboratory
Hospital
Workshop
PHYSICAL HAZARDS• Dust• Vibration• Noise
CHEMICAL HAZARDS• Used Oil
RADIATION HAZARDS• Welding radiation
PSYCHO-SOCIAL HAZARDS
• Overwork
Repairing
Fabricating
Assembling
Tissue Culture
Biological Control
Breeding
Hazard Identification
at Workplace
Plantation
Factory
Workshop
Research
Laboratory
Hospital
Research
CHEMICAL HAZARDS• Chemical for analysis
BIOLOGICAL HAZARDS• Infectious diseases
Lab Analysis
Lab Analysis
Lab Analysis
Hazard Identification
at Workplace
Plantation
Factory
Workshop
Research
Laboratory
Hospital
Laboratory
CHEMICAL HAZARDS• Chemical for analysis
Medical Treatment
Curing Room
X-ray Unit
Hazard Identification
at Workplace
Plantation
Factory
Workshop
Research
Laboratory
HospitalHospital
BIOLOGICAL HAZARDS• Communicable disease
RADIATION HAZARDS• Photo (X-ray)
radiation
JICOSH Extension Seminar
!
HAZARD HANDLING
Modification and Improvement in the
Process
Protection
Eliminating or Minimizing Hazard Source
JICOSH Extension Seminar
WASTE MANAGEMENT
Source Reduction
Recycling & Reusing
Utilization
JICOSH Extension Seminar
Cane
Bagasse
• Derivative Industry(Alcohol, MSG, Cattle Feed)
• Power Generator(Burnt ash is used for farm)
• Derivative Industry(Mushroom, Paper, Cattle Farm)
• Transported to farm as organic fertilizer
Liquid Waste
Juice Sugar
Molasses
Filter Mud
WASTE MANAGEMENT
Solid Waste
WWT
AnaerobePond
(60,900 m3)Buff
erin
g P
ond
(29
,70
0 m
3)
Facu
ltativ
e 3
Pond
(6,1
29
m3
)
Stabilizing Pond(8,100 m3)
Aerobe 1Pond
(18,654 m3)
Facultative 2 Pond(8,400 m3)
Facultative 1 Pond(8,400 m3)
Aerobe 2 Pond
(34,428 m3)
Monitor Pond(4,590 m3)
WASTE WATER TREATMENT
Splitter (Oil and Water)(660 m3)
For irrigation
to the river
Fishing Test
Total Volume = 244,150
m3
Facu
ltativ
e 4
Pond
(6,1
29
m3
)
Facu
ltativ
e 5
Pond
(6,1
29
m3
)
JICOSH Extension Seminar
WASTE WATER TREATMENT
JICOSH Extension Seminar
CONTROL & MONITORING
ENVIRONMENT
• Air Quality Measurement• Water Quality at Resource• Water Waste Quality after
Treatment
WORKER• Pre-employment Medical
Check-up• Periodical Medical Check-up• Pre-replacement Medical
Check-up
JICOSH Extension Seminar
HAZARD SUMMARY
HAZARDS
• Ash• Dust• Noise• Vibration• Heat• Herbicide and
Insecticide• Chemical• Radiation• Poisonous animals
attack• Waste
EFFECT
• Worker’s Health Respiratory System Hearing System Nervous System Heat Stroke & Water
Body losses Acute & Chronic
Intoxication Skin & eyes Irritation GIT disturbance Poison effect of
animal Radiation effects
• Environment Air Pollution Water Pollution Natural Balance Social Aspect
HYGIENE• In-house keeping
ENVIRONMENT• Waste
Management• Waste Water
Treatment• Reforesting,
Green Belt• Routine
Monitoring
HEALTH• Emergency Help• Curative Action• Preventive Action• Promotive Action
JICOSH Extension Seminar
MonthDebit
(M3/day)pH
BOD COD TSS
(ppm)
April 3,371 8.83 30 70 41
May 4,549 8.63 32 76 35
June 3,606 8.53 33 75 20
July 3,514 8.16 41 85 40
August 2,816 8.46 42 90 50
September 4,306 8.31 43 70 42
Tolerable Value
6 - 9 60 100 50
EFFLUENT ANALYSIS BY GOVERNMENT, 2003
JICOSH Extension Seminar
EFFLUENT ANALYSIS BY GOVERNMENT, 2003
0
20
40
60
80
100
BOD COD TSS
April May June July Aug Sept Max
JICOSH Extension Seminar
ParameterAmbient Emission
Measured Tolerable Value
Measured Tolerable Value
SO2 50.11 ug/m3 365 6.32 mg/m3 1000
NOX 26.82 ug/m3 150 69.53 mg/m3 1000
CO 875 ug/m3 10.000 254.23 mg/m3 -
CO2 - - 5.13 % -
O2 - - 11.48 % -
H2S < 0.001 ppm 0.02 - -
NH3 0.003 ppm 2 - -
Total Particle - - 214.26 mg/m3 350
Ash 42.1 ug/m3 230 - -
Noise Level 48.6 dB 70 - -
AIR QUALITY MEASUREMENT BY GOVERNMENT, 2003
JICOSH Extension Seminar
ENVIRONMENT AWARD
JICOSH Extension Seminar
OUR CONSTRAINTS
Human Factor (negative attitude & bad habit)• Indiscipline• Carelessness• Low awareness of the importance of OSH
Need training and OSH campaign
It is the nature of sugar industry to create
hazards• Noise, Heat, Vibration, Ash, etc
Need more budget to provide safety
infrastructures & protection equipment
Daily workers turn-over is high, and they work only in harvesting season.
Need OSH continual campaign
JICOSH Extension Seminar
OUR COMMITMENT
Healthy Worker, Healthy Company
No Serious Hazard
No Environmental Damage
No Occupational Disease
GMP Sugar is the cleanest sugar produced in the region
Thank You