PROMOTIVE ACTION OF WORKER

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PROMOTIVE ACTION OF WORKERS HEALTH, HYGIENE, AND
ENVIRONMENT IN PT. GUNUNG MADU PLANTATIONS INDONES
IA Extension Seminar of JICOSH Ergonomic
Course Presented by dr. Evi Maiselma
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PRESENTATION OUTLINE
Company Overview
Hazard Identification
Hazard Handling
Waste Management
Waste Water Treatment
Control Monitoring
Constraint Commitment
Summary
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PT. GUNUNG MADU PLANTATIONS Cane Plantations
Sugar Factory Lampung, Indonesia www.gunungmadu.co
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COMPANY OUTLINES

• 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)

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PRODUCTION CHART
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THE PLANT SITE
Tokyo

• 7,000 km from Tokyo
• 400 km from Jakarta
• 100 km from Provincial city

Jakarta
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PLANTATIONS AREA

• 7 Area Divisions
• 35,000 Hectares Total Land
• 25,000 Hectares planted with cane

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EMPLOYEES WORKERS
Year Staff Manager Employee Total Daily Workers

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
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EMPLOYEES WORKERS COMPOSITION, 2003
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SITE FACILITIES
FACILITIES RESIDENCE LOCATION RESIDENCE LOCATION RESIDENCE LOCATION RESIDENCE LOCATION RESIDENCE LOCATION RESIDENCE LOCATION TOTAL
FACILITIES Site A I II III IV VI TOTAL

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
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MAIN ACTIVITIES



Cultivation
Laboratory
Health Service
Milling
Crop Maintenance
Waste Management
Processing
Workshop
Harvesting
Steam Generating
Research
Waste Water Treatment
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Hazard Identification at Workplace Plantations
Factory Workshop Research Laboratory Hospital

• PHYSICAL HAZARDS
• Dust
• Vibration
• Noise
• Sunburn

Cultivation
Plantation
Crop Maintenance

• CHEMICAL HAZARDS
• Herbicide insecticide application
• Fertilizer application

• BIOLOGICAL HAZARDS
• Poisonous animal attack
• Parasite infection

Harvesting

• PSYCHO-SOCIAL HAZARDS
• Overwork

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SUGAR PROCESSING FLOW CHART
CANE
BAGASSE
MILLING
IMBIBITION WATER
MIXED JUICE
MILK LIME
FILTER MUD
CLARIFICATION
SO2 GAS
CLEAR JUICE
SO2 GAS
EVAPORATION
SYRUP
BOILING
MASSECUITE
MOLASSES
CURING
WATER
SUGAR
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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

Milling

• PHYSICAL HAZARDS
• Dust
• Ash
• Noise
• Vibration
• Heat

Factory
Clarification

• CHEMICAL HAZARDS
• Chemical for equipment cleaning
• Chemical for processing
• Chemical for Boiler

Evaporation

• PSYCHO-SOCIAL HAZARDS
• Overwork

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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

• PHYSICAL HAZARDS
• Dust
• Vibration
• Noise

Repairing
Fabricating

• CHEMICAL HAZARDS
• Used Oil

Workshop

• RADIATION HAZARDS
• Welding radiation

Assembling

• PSYCHO-SOCIAL HAZARDS
• Overwork

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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

• CHEMICAL HAZARDS
• Chemical for analysis

Research

• BIOLOGICAL HAZARDS
• Infectious diseases

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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

• CHEMICAL HAZARDS
• Chemical for analysis

Laboratory
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Hazard Identification at Workplace Plantation
Factory Workshop Research Laboratory Hospital

Medical Treatment

• BIOLOGICAL HAZARDS
• Communicable disease

Curing Room

• RADIATION HAZARDS
• Photo (X-ray) radiation

Hospital
X-ray Unit
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HAZARD HANDLING
Protection
Modification and Improvement in the Process
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WASTE MANAGEMENT
Source Reduction
Recycling Reusing
Utilization
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WASTE MANAGEMENT
Liquid Waste
WWT
Cane
Juice
Sugar
Molasses
Solid Waste
Bagasse
Filter Mud

• Derivative Industry
• (Alcohol, MSG, Cattle Feed)

• Transported to farm as organic fertilizer

• Power Generator
• (Burnt ash is used for farm)
• Derivative Industry
• (Mushroom, Paper, Cattle Farm)

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WASTE WATER TREATMENT
Anaerobe Pond (60,900 m3)
Facultative 3 Pond (6,129 m3)
Facultative 2 Pond (8,400 m3)
Facultative 4 Pond (6,129 m3)
Facultative 5 Pond (6,129 m3)
Total Volume 244,150 m3
Splitter (Oil and Water) (660 m3)
Buffering Pond (29,700 m3)
Facultative 1 Pond (8,400 m3)
Aerobe 1 Pond (18,654 m3)
Aerobe 2 Pond (34,428 m3)
Fishing Test
Stabilizing Pond (8,100 m3)
For irrigation
Monitor Pond (4,590 m3)
to the river
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WASTE WATER TREATMENT
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CONTROL MONITORING

• WORKER
• Pre-employment Medical Check-up
• Periodical Medical Check-up
• Pre-replacement Medical Check-up

• ENVIRONMENT
• Air Quality Measurement
• Water Quality at Resource
• Water Waste Quality after Treatment

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HAZARD SUMMARY

• HAZARDS
• Ash
• Dust
• Noise
• Vibration
• Heat
• Herbicide and Insecticide
• Chemical
• Radiation
• Poisonous animals attack
• Waste

• EFFECT
• Workers 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

• HEALTH
• Emergency Help
• Curative Action
• Preventive Action
• Promotive Action

• HYGIENE
• In-house keeping

• ENVIRONMENT
• Waste Management
• Waste Water Treatment
• Reforesting, Green Belt
• Routine Monitoring

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EFFLUENT ANALYSIS BY GOVERNMENT, 2003
Month Debit (M3/day) pH BOD COD TSS
Month Debit (M3/day) pH (ppm) (ppm) (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
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EFFLUENT ANALYSIS BY GOVERNMENT, 2003
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AIR QUALITY MEASUREMENT BY GOVERNMENT, 2003
Parameter Ambient Ambient Emission Emission
Parameter 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 lt 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 - -
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ENVIRONMENT AWARD
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OUR CONSTRAINTS
Need training and OSH campaign

• Human Factor (negative attitude bad habit)
• Indiscipline
• Carelessness
• Low awareness of the importance of OSH

Need more budget to provide safety
infrastructures protection equipment

• It is the nature of sugar industry to create
• hazards
• Noise, Heat, Vibration, Ash, etc

Need OSH continual campaign
Daily workers turn-over is high, and they work
only in harvesting season.
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OUR COMMITMENT
No Serious Hazard
No Occupational Disease
No Environmental Damage
Healthy Worker, Healthy Company
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Thank You