Transformation of Batik Small and Medium Enterprises (SMEs

Transcription

Transformation of Batik
Small and Medium
Enterprises (SMEs) Towards
Sustainability
Through Cleaner
Production Practice
Nik Meriam Nik Sulaiman
Inn0vation for Inclusive Development
Transformation of Batik Small and
Medium Enterprises (SMEs) Towards
Sustainability Through Cleaner
Production Practice
TABLE OF CONTENTS
Module Overview
... 3
Lesson 1: Current Practice of Batik Making ... 10
Lesson 2: Sharing of Experience Among Participants ... 24
Lesson 3: Cleaner Production Approach ... 29
Lesson 4: Chemical Safety and Management ... 47
Lesson 5: Safe Workplace Environment ... 81
Lesson 6: Waste and Residues Management ... 92
Lesson 7: Energy Management ... 103
Lesson 8: Inventory Management ... 111
Lesson 9: Site Visit ... 127
Lesson 10: Towards Eco-Labelling/Certification ... 133
Lesson 11: Wrap-Up and Evaluation ... 143
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Transformation of Batik Small and Medium Enterprise s (SMEs) Towards
Sustainability Through Cleaner Production Practice
Module Overview
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Introduction
In Malaysia, SMEs are divided into two categories - manufacturing and services and other sectors.
Manufacturing SMEs should have annual sales turnover not exceeding RM50 million or full-time
employees not exceeding 200 workers. Services and other sectors SMEs should have annual sales
turnover not exceeding RM20 million or full-time employees not exceeding 75 workers. Batik
industry can be regarded as one of the manufacturing SMEs in Malaysia.
Batik is a traditional form of textile making which uses wax as the resist material to produce the
desired design. In Malaysia, the batik industry comprises a range of players from designers and
producers, to the traders. Yet, the core of the industry are the batik makers who, by and large,
are small-time, family-owned enterprises that make a living producing batik pieces which are
marketed by the traders. As expected, the margin of profit made by the batik makers is relatively
meagre compared to the traders.
Since the batik makers are at the back end of the industry, the buyers of batik do not know much
about their practices. Until now, the processes and activities involved in producing batik remain
inefficient in terms of water usage, unsafe handling of chemicals, and poor work environment
and the absence of any kind of treatment of the copious amounts of highly-coloured wastewater
that is produced.
Some attempts have been made to transform the batik industry to become more environmentfriendly and cost-effective, yet maintain its attractiveness as a traditional ethnic craft. In
particular, the EU-SWITCH ASIA Program initiated a Cleaner Production awareness program for
batik makers in Malaysia and Indonesia in 2010. The Department of Environment of Malaysia has
also implemented a demonstration case study on one factory towards achieving green batik
product.
Yet, the transformation process and mindset of the batik producers towards a more sustainable
process needs to be strengthened so that the momentum achieved in the last few years can be
maintained and improved. Thus, the objectives of this training package are to further enhance
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the lessons learnt in the form of easily understood and easy to follow teaching materials aimed at
providing awareness of the need to upgrade the batik-making process as well as to provide stepby-step guides to implement practical ways to improve resource utilisation and waste
management.
The module intends to outline an integrated holistic approach towards achieving the above
objectives and is thus divided into the following sections:
1)
Current practices and its limitations
2)
The cleaner production approach
3)
Chemical safety and management
4)
Safe workplace environment
5)
General good housekeeping measures
6)
Inventory management.
Target Users and Learners
These are practical lessons and are devised specifically to guide those who are involved
directly in producing batik. This learning package can also help those first-timers to start their
business on the right track while improving the process for those who are already in the batik
making sector.
This learning package can also be used by trainers involved in crafts industry such as
government agencies, crafts institutes, and community colleges.
2.1 Class size
The module is designed for a maximum of 20 participants.
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2.2 Basic qualifications/prerequisites
Participants must be involved directly in the batik making process and possess basic
entrepreneurial skills which include interpersonal, marketing, and communication skills.
However, participants may not necessarily possess tertiary education.
Target Learning
Objectives and Outcomes
3.1 Objectives
1. To transfer and to provide inclusive solutions for local batik practitioners towards
a sustainable and competitive batik industry, and
2.
To foster a symbiotic relationship between the batik Small and Medium
Enterprises (SME) and other stakeholders (academia, end-users, suppliers,
economists, and technologists)
3.2 Outcomes
At the end of this module, participants will be able:
1. To understand the basic concept of cleaner production, especially in batik making
processes
2. To practise or apply cleaner production approach in their batik making processes,
and
3.
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To produce eco-batik products which can go for eco-labelling certification
Module Summary
Session
1
Duration
(hours)
2
Lessons
Activities/Description
Current Practices of Batik-Making
1) Presentation
This session aims to impart current trend or
A one-hour talk by a technical
practices prevalent among the batik-making
expert.
community that tend to harm both
environment and the safety of workers. The
2) Video-screening
current practice involves inefficient resource
Video presentation on batik
utilisation, poor energy management, and non-
making processes and their
competitive marketing strategy. Major issues
impact on the environment
will be identified for discussion.
and workers.
3) Entrance survey
Survey form will be
distributed to obtain
information on participants’
level of knowledge prior to
the training.
2
3
Sharing of Experience among Participants
1) Group discussion
In this session, participants will be able to share
Interactive session between
their experiences in dealing with batik making
participants to exchange their
procedures. This session is important to get a
experience, knowledge, and
general idea on how they handle their
views pertaining to batik
resources and wastes generated.
making and cleaner
production.
3
4
Cleaner Production Approach
To introduce the basic concept of cleaner
1) Presentation
Talk by technical expert.
production to the participants including the
definition, benefits as well as the success
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factors for cleaner production implementation.
Methodology for cleaner production
implementation will also be discussed in this
session.
4
3
Chemical Safety and Management
1) Presentation
To introduce the basic understanding and
Two hours talk by technical
concept of the safety and management of
expert.
chemical agents used in the process of making
batik.
5
3
Safe Workplace Environment
1) Presentation
To introduce the basic understanding and
concept of the issue of workers’ and workplace
expert.
safety.
6
3
Waste and Residues Management
1) Presentation
To introduce the basic concepts of waste
management including definitions of waste,
expert.
residue characteristics, and proper
management of residues and waste.
7
3
Energy Management
1) Presentation
To share appropriate and strategic tools in
promoting sustainable energy management in
expert.
batik making processes (both employers and
employees).
8
3
Inventory Management
1) Presentation
To promote the importance of inventory
management / good housekeeping practices
expert.
for local batik practitioners towards cleaner
batik production for SME.
9
4
Site Visit
1) Site visit
This session serves as a platform for
2) Hands-on training
participants to practise what they have learnt
during previous sessions.
10
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2
Towards Eco-labelling / Certification
1) Group Discussion
To highlight the importance of certification to
2) Q&A session
produce eco-product.
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2
Wrap-up and Evaluation
1) Talk
This is the final session of the training.
2) Q&A session
3) Exit survey
Survey form will be
distributed to obtain
information on participants’
level of knowledge after the
training.
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Lesson 1
Current Practice
of Batik Making
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Syllabus Outline
Objective
This session aims to impart current trends or practices prevalent among the batik making
community that tend to harm both the environment and the safety of workers. Major issues will
be defined in this session and further discussed in the following session.
Learning Assessment
Discussion on topics relating to current trends and practices of batik making.
Targeted Outcome
Participants should understand the issues arising from current practice that lead to harming of
the environment and safety and health of the workers.
Lesson topics
1. Introduction
a. Definition of batik: general & Malaysian Standard (SIRIM)
2. Malaysian Batik Industry
3. Challenges in batik industry
4. Sustainability development in batik industry
5. Batik making process
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Current Practices of Batik Making
A.
Introduction
Current challenges in the batik industry include:
i.
Copycat-homogenous products:
Need for development of human capital and training.
ii.
Over-supply:
Systematic and effective marketing strategies.
iii.
Lack of quality control:
Benchmarking and stronger reputation and culture needed.
iv.
Lack of technology:
Extensive usage of water during processing and production of
wastewater contaminated with dye and chemicals.
v.
Global competitors:
Local batik industry has issues on intellectual property law where other
countries -- for example, China and Vietnam -- had imitated the design of
the local batik producers with lower price that resulted in a negative
impact on the local products of the Malaysian batik industry.
In the Malaysian market, there are two major types of batik; these are hand-drawn batik
and block-printed batik. Both have different techniques. Hand-drawn batik is drawn on
the fabric with hot liquid wax by using a metal object called Canting. Meanwhile, in blockprinted batik a block is dipped into the wax and printed onto the fabric.
The manufacturing process consists of many steps (refer Figure 1.1 and Figure 1.2). The
raw materials required, besides cloth, are dyes as colouring agents, chemicals to fix the
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color, softener, detergent and wax as the resist material. The process requires large
amounts of water for washing and rinsing. In addition, electricity for lighting and
mechanical equipment, and natural gas and firewood to provide energy serve a utility
function in the batik process.
B.
Relevant lesson materials
 Issues of processing to the environment
 To the safety of workers and workplace environment
C.
Case studies
 Slides
 Video
D.
Evaluation material
 Form F1:
E.
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Entrance survey
References
Introduction
Objective
Learning Assessment
This session aims to impart current
Discussion on topics relating to current
trend or practices prevalent among
trends and practices of batik making.
Batik community that tend to harm both
environment and the safety of workers.
Major issues will be defined in this
session and further discussed in the
following session.
Targeted Outcome
Participants will understand the issues
rising from current practice that lead to
harm of environment and safety of
workers.
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WHAT IS BATIK?
General & SIRIM Definition
General definition
Batik is a decorated fabric containing various color and pattern
SIRIM definition of batik
Based on Batik Malaysia ( Kraftangan ) in Malaysian Standard Article 3.1 ( batik definition ) MS
692 : 2007 (Department of Standards Malaysia):
“…a process of painting, dyeing and printing fabric bymaking use of a physical resist
technique –covering areas of fabric with a physical dye-resistant substance, mainly wax,
to prevent these areas from dye penetration and finally removing these dye-resistant
substance to reveal the design…”.
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MALAYSIAN BATIK INDUSTRY:
General Information
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Challenges in
Malaysian Batik Industry
Batik
Challenges
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Towards Sustainability
1. The strategy and management control system in batik industry was moderated by
culture, environment and technology development (Ismail et al., 2012)
2. Batik is an important industry in Malaysia but it is hardly famous for its green
credentials?
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CHALLENGES IN BATIK INDUSTRY:
Environmental Sustainability
1. Batik factories operate with excessive use of water during fixation, soaking, rinsing and
washing process
2. In terms of material usage, there is excess wax during application of wax to create design,
while chemical, dyes and also bleaching agents are used during fixation, coloring and
washing.
3. All of them and mixtures of them are categorized as potentially harmful to people and
the environment.
4.
In addition, many batik workers are ill-equipped and do not wear proper protective gear
when handling dangerous substances?
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Batik Making Process
Preparation of Cloth
Design & Canting
Color
Fixing (Silicate)
Soaking
Dewax
Rinse
Dry
Figure 1.1: Process flow in batik making.
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color
cloth
design
Color fixation
Dewax
soaking
Rinse
Dry
Figure 1.2: Batik process
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EVALUATION MATERIAL
FORM F1: ENTRANCE SURVEY
Transformation Of Batik Smes Towards Sustainability
Through Cleaner Production Practice
DATE
:
NAME
:
COMPANY
:
ADDRESS
:
CONTACT NO
:
Please use the prescribed scale to rate the level of your proficiency in the listed Programme
Outcomes at TIME OF ENTRANCE to the programme.
Rating
0
1
2
3
4
5
Level of proficiency
None
Poor
Fair
Average
Good
Excellent
Ratings
Outcomes
Items
0
1. Build deeper
understanding on
the basic concept of
cleaner batik
production
a) I can describe what is clean batik production
2. Describe the practice
or the application
cleaner production
approach
a) I can explain the application of cleaner
production
which can go for
eco-labelling
certification
a) I am able apply the knowledge for a better
production process for eco-labelling
certification
1
2
3
4
b) I am able to explain the concept of clean
production
c) I can explain why clean production is crucial
b) I am able to apply the cleaner production
approach in my current production
b) I am able to produce eco-batik products in
compliant with eco-labelling certification
Other comments:
_______________________________________________________________________________
Thank you. This survey will help us to better understand your needs for the continual
improvement of the quality of future programmes.
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5
References
Arney, S. (1987). Malaysian Batik: Creating New Traditions. Kraftangan Malaysia
Ismail, T., Wiyantoro, L, S., Meutia, & Muchlish, M. (2012). Strategy, Interactive Control
System and National Culture: A Case Study of Batik Industry in Indonesia. Journal of
Procedia - Social and Behavioral Sciences, 65, 33 – 38
Lin, C. L. (2007). Batik: Creating an Identity. Didier Millet
Nieminen, E., Linken, M., Tobler, M., &Beke, B. V. (2007). EU cost action 628: Life cycle
assessment (LCA) of textile products eco-efficiency and definition of best available
technology (BAT) of textile processing. Journal of Cleaner Production, 15, 1259 – 1270.
Oparinde, S. S. (2012). Batik as cultural identity of the Yoruba: Hand colouring technique
and applications, possibility of adaptations. Journal of Arts Science and Commerce, 2(3),
31 – 41.
Qua, C. (2007). Malaysia's Living Heritage: Batik Inspirations. Pustaka RBS.
Yunus, Noor Azlina. (2014). Malaysian Batik: Reinventing a Tradition. Tuttle Publishing.
Video materials:
Video V1.1
Batik Documentary
Link: http://www.youtube.com/watch?v=-nsMFIZfBiE
Video V1.2
Clean Batik Initiative (CBI): Awareness video
Link: http://www.youtube.com/watch?v=odk-Bvl3vrA
Video V1.3
The Process of Making Batik - Artisans at Work
Link: http://www.youtube.com/watch?v=MAm9Z_GMy3k
Evaluation Material
Form F1:
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Entrance Survey
Lesson 2
Sharing of
Experience Among
Participants
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Syllabus Outline
Objective
In this session, participants will be able to share their experiences in dealing with batik making
procedures. This session is important to get a general idea of how they handle their resources
and generated waste.
Learning Assessment
Sharing of views, insights, and valuable experiences in batik making industry amongst local batik
practitioners.
Targeted Outcome
Participants will be able to understand, share and discuss different scenarios and challenges in
batik making industry for SME.
Lesson topics
1. Introduction
2. Sharing Session - insights into the many challenges facing the batik making industry present and future specified towards resources and generated waste management
3. Discussion on the latest trends, developments, and potential solutions in the sector with
experts and experienced practitioners
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Sharing of Experience among Participants
A.
Introduction
In the second session, participants will be actively involved with engaging experience
sharing activities. Among line-up of activities for this session includes interactive plenary
sessions including overview of the topic, presentation and discussion. Participants should
be eager to learn from others but also to share their knowledge and experience. Hence,
networking is a key aspect of this session.
B.
Case studies
Presentation of exemplary case studies by experts on the importance of (1) resource
management; and (2) generated waste management in the batik industry
C.
 Guided info notes for participants to relate experiences shared in this session
D.
Evaluation material
 Discussion among participants;
 Mapping of the key elements in experience sharing session.
E.
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References
Introduction
Objective
Learning Assessment
In this session, participants will be able
Sharing of views, insights, and valuable
to share their experiences in dealing
experiences in batik making industry
with batik making procedures. This
amongst local batik practitioners.
session is important to get a general
idea on how they handle their resources
and the waste they generate.
Targeted Outcome
Participants will be able to understand,
share and discuss different scenarios
and challenges in batik making industry
for SME.
Guideline Info Notes
 Participants are required to seat in a small group of 4 or 5
 Each group will be provided with marker pens & flipchart papers (84.1cm x 118.9cm)
 Each participant will be given 3-5 minutes to share within their group the following
elements:

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their experience in batik,

years of involvement in batik making SME,

Processes of making batik,

Environmental incidents (if any),

Challenges (Economy/Social/Environment) in managing batik making SME.
 Later, each group will be required to present their key-elements of their sharing session
mapped-out on paper as well as oral presentation by group representative (each group:
maximum of 5 minutes)
Summary of Discussion
 their experience in batik,
 years of involvement in batik making SME,
 Processes of making batik,
 Environmental incidents (if any),
 Challenges (Economy/Social/Environment) in managing batik making SME.
References
Experiential Learning module:
http://reviewing.co.uk/research/experiential.learning.htm
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Lesson 3
Cleaner
Production
Approach
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Syllabus Outline
Objective
To introduce the basic concept of cleaner production to the participants including the definition,
benefits as well as the success factors for cleaner production implementation. Methodology for
cleaner production implementation will also be discussed in this session.
Learning Assessment
Discussion, individual assignment.
Targeted Outcome
At the end of the session, participants will be able to understand the concept of cleaner
production and its importance to the batik industry.
Lesson topics
1. Introduction
 Definition
 Benefits
 5R concept
2. General methodology of cleaner production approach
3. Practical Implementation of Cleaner Production
a. Identification of hotspots
b. Eco-map
c. Root cause analysis
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Cleaner Production Approach
A.
Introduction
The term Cleaner Production (CP) was defined by the United Nations Environment
Programme (UNEP) as ‘the continuous application of an integrated environmental
strategy to processes, products and services to increase efficiency and reduce risks to
humans and the environment’ (UNEP, 2014). Cleaner production involves applying knowhow, improving technologies, and all, changing attitudes in many places.
For products, the strategy focuses on reducing impacts along the entire life of the
products and services, from design to the usage of an ultimate disposal. For production
processes such as in the making of batik, cleaner production includes:
 the efficient use of materials e.g. cloth and dye;
 the efficient use of energy e.g. electricity and water;
 the elimination of toxic and dangerous materials e.g. sodium silicate; and,
 reduction of emissions and wastes at the source e.g. fumes and wastewater.
Benefits of Cleaner Production
management; and (2) generated waste management in the batik industry.
Case studies
management; and (2) generated waste management in the batik industry.
5R concept
The words starting with the letter R, representing five environment-conscious words,
have been adopted as a key mnemonic for batik activities. The 5R concepts include the
three R words of the 3Rs that characterise a recycling-oriented society; two additional
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words can be "Refuse" and "Reform". The concept will be applied to the waste and
materials involved in the batik activities.
 Reduce: Reduce usage and waste material
 Recycle: Collect and send materials to be recycled for further use
 Reuse: Reuse waste material without processing
 Refuse: Avoid purchase of environmentally burdensome materials whenever
possible
 Reform: Reuse materials in a different form.
Success factors
Basically, there are four enablers for cleaner production implementation:
 Best management practices
 Good Science & Technology
 Market realities
 Political realities
Methodology of Cleaner Production
Cleaner Production methodology outlines the audit process into six steps and 18 tasks.
Eco-tools for CP implementation in batik
industry
 Identification of hotspots: areas that cause losses to the process, whether
materials, energy or safety.
 Eco-mapping: a visual and practical tool that helps SME managers and
employees to analyse and manage the environmental performance of small
companies and craft industries.
 Root Cause Analysis: an approach for identifying the underlying causes of why an
incident occurred.
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B.
 Slides / notes
 Root cause flowchart - In order for any intervention measures to take place, we
must identify the problem/root cause. Root cause analysis allows participants to
identify losses to environment and to the workers. Loss, hereby, includes
material loss, energy loss, lack of workplace safety, and the decline in product
quality.
C.
Evaluation material
 Identify the hotspots - Participants will be asked to identify hotspots at their
workplace
 Eco-map - Participants will be asked to draw an eco-map of their workplace.
 Root cause analysis - Participants will be asked to do a root cause analysis, using
inputs from their eco-map and hotspots identification to determine.
D.
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References
Introduction
Objective
Learning Assessment
To introduce the basic concept of
Discussion, individual assignment
Cleaner Production to the participants
including the definition, benefits as well
as the success factors for Cleaner
Production implementation.
Methodology for Cleaner Production
implementation will also be discussed in
this session.
Targeted Outcome
At the end of the session, participants
will be able to understand the concept
of Cleaner Production and its
importance to the batik industry.
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CP- Definition
“Cleaner production means the continuous application of an integrated, preventative
environmental strategy to processes, products and services to increase eco-efficiency and
reduce risks to humans and the environment”
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CP- Benefits
 Cleaner Production can

reduce operating costs,

improve profitability,

worker safety and

reduce the environmental impact of your business.

Companies are frequently surprised at the cost reductions achievable .
Success Stories For CP Implementation
 Bangladeshi Textile - http://www.youtube.com/watch?v=Q7VquxNGZEI
 CP Concept STENUM - http://www.youtube.com/watch?v=Q7VquxNGZEI
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CP - 5R Concept
Recycle
Reform
Refuse
5R
Reduce
Reuse
 Water
 Water
 Dyes
 Wax
 Electricity
 Combustion
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CP - Methodology
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CP - Implementation to Batik Industry
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Examples of Tools
to Implement CP: Hotspot Identification
Hotspot
Hotspot division
Chemical management
35%
Energy consumption
27%
Water consumption
20%
Raw material usage
18%
 Major hotspot - chemical management (35%):

Chemicals not properly placed

Located in different places

Do not have specific shelf to store their chemicals

No label on each container of chemicals

Did not document the usage of chemicals
 2nd major hotspot - energy consumption (27%):
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
Did not make significant effort to reduce energy usage

Do not have safety signage for energy conservation
Examples of Tools
to Implement CP: Eco-Map
Eco-mapping: a visual and practical tool that helps SME managers and employees to analyse
and manage the environmental performance of small companies and craft industries.
Eco-mapping has several functions as:
 an inventory of environmental practices and problems
 a systematic method of conducting an on-site environmental review and audit
 a tool that allows employee involvement and participation
 a support for training and awareness, and to assist with internal and external
communication
 an easy way to document and track environmental improvements
 a catalogue of immediate small positive actions.
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Examples of Tools
to Implement CP: Root Cause Analysis
No/Improper PPE
No PPE provided
Wrong technique
used
No SOP/ training
provided
Skin irritation
Root Cause Analysis: an approach for
identifying the underlying causes of why an
incident occurred.
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Examples of Tools
to Implement CP: GHK
Good housekeeping (GHK) & 5R practices:
 Chemical safety and management
 Safe workplace environment
 Waste and Residual Management
 Energy Management
 Inventory Management
 Raw material documentation (cloth, chemical, dyes, wax)
 Product documentation (batik sarung, kaftan, kain ela)
 Workers documentation (attendance, health record)
 Utilities documentation (water and electricity bill)
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FORM 3.1: ECO-MAPPING FORM
NAME:
DATE:
COMPANY:
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FORM 3.2: ROOT CAUSE ANALYSIS
NAME:
DATE:
COMPANY:
To complete root cause analysis, you will need:
 Eco-Map;
 List of Hotspots
No.
Root cause to be
improved:
1
2
3
4
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References
Green Industry Virtual Centre. 2011. Cleaner Production Methodology.
Retrieved August 7, 2014, from
http://cp.doe.gov.my/givc/introduction/background/methodology/
UNEP. 2014. Resource Efficient and Cleaner Production.
Retrieved August 6, 2014, from http://www.unep.fr/scp/cp/
Eco-Mapping.
Retrieved August 5, 2014, from http://www.ecomapping.org/en/toolsmethodes/ecomapping.html
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Lesson 4
Chemical Safety
and Management
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Syllabus Outline
Objective
To introduce the basic understanding and concepts of the safety and management of chemical
agents used in the process of making batik.
Learning Assessment
Discussion and individual assignment.
Targeted Outcome
At the end of the session, participants will be able to understand the concept and the importance
of safety and management of chemical agents used in batik industry.
Lesson topics
1. Introduction
2. Types of chemicals used in the batik industry- identification and characteristics of
chemicals
3. Mishandling of chemicals (danger and effects
4. Proper management of the chemicals How to handle? Proper labelling, good inventory,
signage
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Chemical Safety and Management
A.
Introduction
Chemical safety and management is an important topic that will be covered in this
session. In batik making SME, chemicals are used in daily basis for several stages. Thus,
safety issues and proper management of chemicals used should not be taken lightly.
Occupational Safety and Health Regulations
A national law of Malaysia, Occupational Safety and Health Act (1994) allows OSHA to
issue regulations for safety and health at workplace. The Act aims to promote safety and
health awareness, and establish an effective safety organization of a business and
effective performance through self-regulation schemes designed to suit the particular
industry or organization. The long-term goal of the OSHA 1994 is to create a healthy and
safe working culture among all Malaysian employees and employers. OSHA 1994 covers
all economic activities, but not for work on board ships and arm forces. To make sure the
objectives are achieved, OSHA 1994 came out with seven (7) sub-regulations which are:
1. OSH (Safety and Health Policy)
2. OSH (Safety Officer) 1997
3. OSH (Safety and Health Committee) 1994
4. OSH (Classification, Packaging and Labelling of Hazardous Chemical) 1997
5. OSH Use and Standards of Exposure of Chemicals Hazardous To Health)
Regulations 2000
6. OSH (Control of Industrial Major Accident Hazard) Regulation 1996
7. OSH (Notification of Notification of Accident, Dangerous Occurrence,
Occupational Poisoning and Occupational Disease) Regulations 2004.
Hazard Classification
Generally, any chemical that presents a physical hazard or a health hazard is considered a
hazardous chemical (United States OSHA's Hazard Communication Standard (HCS)]. The
HCS definitions for physical and health hazards are:
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 Physical hazard
 Health hazard
 Environmental Hazard
Types of Chemicals Used in the Batik Industry
(Source: Clean Batik Initiative - Manual for handling of chemical Substances Precautions
and First Aid)
In terms of material usage, wax will be applied to cloth to create design, while other
chemicals such as dyes and also fixing agents are used during colouring, fixation,
washing. All of them and mixtures of them are categorized as potentially harmful to
people and the environment.
50 |
51 |
52 |
53 |
54 |
55 |
56 |
57 |
58 |
59 |
General Management of Chemical
Proper management of chemical is crucial to prevent and/or control issues of
environmental, health and safety within any batik workplace. Some of the precautionary
measures that can be taken by the producers are:
 Good inventory with proper materials safety data sheet (MSDS)
 Proper labelling on every bottle or container used to store chemical agents
 Ensuring all workers are provided with personal protective equipment
 Appropriate signage around working area, such as safety signs (e.g. fire
extinguisher sign), ergonomic (e.g. lifting techniques) and electrical equipment
sign.
Figure 4.1: Examples of safety sign, electrical equipment sign, and
ergonomics
B.
 Safety data sheet
 List of personal protective equipment that is appropriate for the batik industry
 Examples of labelling and signage relevant for usage in batik workplace
C.
60 |
References
Introduction
Objective
Learning Assessment
To introduce the basic understanding
Discussion, individual assignment.
and concept on the safety and
management of chemical agents used in
the process of making batik.
Targeted Outcome
At the end of the session, participant
will be able to understand the concept
and the importance of safety and
management of chemical agents used in
batik industry.
61 |
General definition of hazards
Generally, any chemical that presents a physical hazard or a health hazard is considered a
hazardous chemical (United States OSHA's Hazard Communication Standard (HCS)]. The HCS
definitions for physical and health hazards are:
Physical hazard a chemical for which there is scientifically
valid evidence that it is a combustible liquid, a compressed gas,
explosive, flammable, an organic peroxide, an oxidizer,
pyrophoric, unstable (reactive) or water-reactive.
Health hazard means a chemical for which there is
statistically significant evidence based on at least one study
conducted in accordance with established scientific principles
that acute or chronic health effects may occur in exposed
employees. The term "health hazard" includes chemicals which
are carcinogens, toxic or highly toxic agents, reproductive
toxins, irritants, corrosives, sensitizers, hepatotoxins,
nephrotoxins, neurotoxins, agents which act on the
hematopoietic system, and agents which damage the lungs,
skin, eyes, or mucous membranes.
Environmental Hazard means chemicals or mixed of
chemicals discharge untreated into environment can cause
harmful to aquatic environment (acute or chronic) and harmful
to ozone layer.
62 |
Malaysia: OSHA (1994)
 A national law of Malaysia, Occupational Safety and Health Act (1994) allows OSHA to
issue regulations for safety and health at workplace.
 7 regulations under OSHA (1994) to comply;

OSH (Safety and Health Policy)

OSH (Safety Officer) 1997

OSH (Safety and Health Committee) 1994

OSH (Classification, Packaging and Labeling of
Hazardous Chemical) 1997

OSH Use And Standards Of Exposure Of Chemicals
Hazardous To Health) Regulations 2000

OSH (Control of Industrial Major Accident Hazard)
Regulation 1996

OSH (Notification of Notification Of Accident,
Dangerous Occurrence, Occupational Poisoning And
Occupational Disease) Regulations 2004.
63 |
Types of Chemical Used in Batik Process
 Synthetic dyes

Remazol, etc
 Fixation agents

sodium silicate, soda ash, etc
 Wax, paraffin
64 |
Common Characteristic of Chemicals
Mishandling of chemicals
(danger and effects)
Types of
Function
Characteristics
Characteristics
Chemicals
Batik Wax
Non-hazardous component
Health hazard: Inhalation
(Breathing): Vapours emitted
from molten wax are expected
65 |
to have a low degree of irritation
by inhalation.
Fire hazard:
This material may burn but will
not ignite readily. Keep away
from all sources of ignition.
Sodium Silicate
Fixative for
A powdered or flaked solid substance.
dyeing
Strong irritant to skin, eyes, and
mucous membranes. May be toxic by
ingestion. Concentrated aqueous
solutions used as a glue.
Also known as Water glass or liquid
glass
Resin
Any natural or synthetic organic
Health Hazard:
compound consisting of a non-
The primary hazard with resins is
crystalline or viscous liquid substance
direct contact. Problems range
from staining and irritation to
organ damage, and many
substances are suspected or
known carcinogens.
Most resins are skin sensitizers,
meaning that symptoms can
develop or become worse after
repeated or prolonged contact.
66 |
Napthols
Dye
Naphthol dyes are due to their
hazardous and carcinogens natures not
produced in the
European Union (EU) any longer and
are banned for usage in the EU as well
as for import on ready made products.
General Guideline: Handle With Care
 Do not smoke or eat when handling chemicals
 Wear at all times protective clothes and equipment
 Rubber boots – do not wear sandals!
 Hand gloves up to your elbow
 Safety goggles, your eye can not be replaced, blindness is a final act and a disaster for
you and your family
 Protective clothes: T- Shirt, trousers and a rubber apron
67 |
General Guideline:
Proper Management of Chemicals
 Good inventory with proper materials safety data sheet (MSDS)
 Proper labelling on every bottles or containers used to store chemical agents
 Ensuring all workers are provided with personal protective equipment
 Appropriate signage around working area such as safety sign (e.g. fire extinguisher sign),
health sign (e.g. lifting techniques) and electrical equipment sign
Batik Application:
How to Keep/Store Chemical?
No
Current Situation
GHK practice
1
Dye containers are placed everywhere
Provide a rack & dye containers
No designated place to put dye containers
68 |
69 |
No
Before
After
2
Chemical containers are not compatible with the
Provide a closed container to put the resin and
chemical characteristics of wax and resin
wax
MATERIAL SAFETY
DATA SHEET:
Paraffin Wax
Product Name: Paraffin Wax
1. Chemical Product Identification
Product Name: Paraffin Wax
Product Code: SP-173
Generic Name: Paraffin Wax
INCI Name: Paraffin
Chemical Family: Mineral Wax
Emergency Telephone Numbers:
800-255-3924 ChemTel. (United States)
+ 1 01 813-248-0585 (Outside the United States)
Health Hazards: None anticipated
Physical Hazards: This material may burn but will not ignite readily. Keep away from all
sources of ignition.
 Physical Form: Solid -- Slab or Pastille Form
 Appearance: White
 Odor: None to slight – characteristic
NFPA Hazard Class:
 Health: 0 (Least)
 Flammability: 1 (Slight)
 Reactivity: 0 (Least)
70 |
2. Composition/Information on Ingredients
Hazardous Components: None
Other Components
100% Volume
Exposure Guideline
Limits
Agency
Type
CAS #8002-74-2
---------None Known-------
3. Hazards Identification
POTENTIAL HEALTH EFFECTS:
Eye: Solid material is not expected to be an eye irritant; however, contact with molten
wax may cause thermal burns. Vapors from molten wax may cause watering of the eyes.
Skin: Solid material is not expected to be a skin irritant; however, skin contact with
molten wax may cause thermal burns. No harmful effects from skin absorption are
expected.
Inhalation (Breathing): Vapors emitted from molten wax are expected to have a low
degree of irritation by inhalation.
Ingestion (Swallowing): No harmful effects expected
Signs and Symptoms: Effects of overexposure may include irritation of the nose and
throat
Cancer: No data available
Target Organs: No data available
Developmental: No data available
Pre-Existing Medical Conditions: None known
4. First Aid Measures
Eye: If irritation or redness develops from exposure to fumes generated during hot-melt
processing operations, move victim away from exposure and into fresh air. Flush eyes
with clean water. If irritation or redness persists, seek medical attention. For contact with
the molten material gently open eyelids and flush affected eye(s) with cold water. Seek
immediate medical attention.
Skin: For contact with molten material, leave material on skin and flush or immerse
affected area(s), using cold water. Seek medical attention.
71 |
Inhalation (Breathing): If respiratory symptoms develop from exposure to fumes emitted
by the molten material, move victim away from source of exposure and into fresh air.
If symptoms persist, seek medical attention. If victim is not breathing, immediately begin
artificial respiration. If breathing difficulties develop, oxygen should be administered by
qualified personnel. Seek immediate medical attention.
Ingestion (Swallowing): First aid is not normally required for the solid material; however,
if molten material is swallowed, seek immediate medical attention.
Note to Physicians: None
5. Fire-fighting Measures
FLAMMABLE PROPERTIES:
Flash Point: 400 Degrees F (COC) Minimum
OSHA Flammability Class: Not regulated
LEL/UEL: No data
Autoignition Temperature: No data
Burn Rate (solids): No data
Unusual Fire & Explosion Hazards: This material may burn, but will not ignite readily.
Extinguishing Media: Dry chemical, foam, water, sand, or earth is recommended.
Fire-fighting Instructions: Emergency responders in the danger area should wear bunker
gear and self-contained breathing apparatus for fires beyond the incipient state (29CFR
1910.156). In addition, wear other appropriate protective equipment as conditions
warrant (see Section 8). Isolate danger area, keep unauthorized personnel out. Contain
spill if it can be done with minimal risk. Move undamaged containers from danger area if
it can be done with minimal risk. With water, cool equipment exposed to fire if it can be
done with minimal risk.
6. Accidental Release Measures
This material may burn but will not ignite readily. Keep all sources of ignition away from
spill/release. Stay upwind and away from spill. Isolate danger area and keep
unauthorized personnel out. Contain spill if it can be done with minimal risk. Wear
appropriate protective equipment, including respiratory protection, as conditions
warrant (see Section 8). Prevent spilled material from entering sewers, storm drains,
other unauthorized treatment drainage systems, and natural waterways. Notify fire
72 |
authorities and appropriate federal, state, and local agencies. Cleanup under expert
supervision is advised. Minimize dust generation. Sweep up and package appropriately
for disposal.
7. Handling and Storage
Handling: Wash thoroughly after handling. Do not wear contaminated clothing or shoes.
Use good personal hygiene practice. "Empty" containers retain residue (liquid and/or
vapor) and may be dangerous. Do not pressurize, cut, weld, braze, solder, drill, grind, or
expose such containers to heat, flame, sparks, or other sources of ignition. They may
explode and cause injury or death. All containers should be disposed of in an
environmentally-safe manner and in accordance with governmental regulations. Before
working on or in tanks which contain or have contained this material, refer to
Occupational Safety and Health Administration Regulations, ANSI Z49.1 and other
governmental and industrial references pertaining to cleaning, repairing, welding, or
other contemplated operations.
Storage: Keep container(s) tightly closed. Use and store this material in cool, dry, wellventilated areas away from heat and all sources of ignition. Store only in approved
containers. Keep away from any incompatible material (see Section 10). Protect
container(s) against physical damage.
8. Exposure Controls/Personal Protection
PERSONAL PROTECTIVE EQUIPMENT (PPE):
Respiratory: No respiratory protection is required when working with the solid material.
If airborne concentrations of wax fumes, generated from molten wax, are expected, a
NIOSH/MSHA approved air purifying respirator with a dust/mist/fume filter may be used.
Protection provided by air purifying respirators is limited (see manufacturer's respirator
selection guide). Use a positive pressure air supplied respirator if there is potential for an
uncontrolled release, exposure levels are not known, or any other circumstances where
air purifying respirators may not provide adequate protection. A respiratory protection
program that meets OSHA's 29 CFR 1910.34 and ANSI Z88.2 requirements must be
followed whenever workplace conditions warrant a respirator's use.
73 |
Skin: Not normally required for solid material. The use of thermally-resistant gloves is
recommended when there is potential for exposure to molten wax.
Eye/Face: Approved eye protection to safeguard against potential eye contact, irritation,
or injury is recommended.
Other Protective Equipment: A source of clean water should be available in the work
area for flushing eyes and skin. Impervious clothing should be worn as needed.
9. Physical and Chemical Properties
Note: Unless otherwise stated, values are determined at 20 Degrees C (68 Degrees F) and
760 mm Hg (1 atm).
Flash Point: 400 Degrees F Minimum
Flammable/Explosive Limits (%): No data
Autoignition Temperature: No data
Burn Rate (solids only): No data
Appearance: White
Physical State: Solid -- Pastille Form
Odor: None to slight - characteristic
Vapor Pressure (mm Hg): No data
Vapor Density (air+1): No data
Boiling Point: >650 Deg. F/343 Deg. C
Melting Point: 138 - 144 Deg. F/58.9-62.2 Deg. C
Solubility in Water: Negligible
Specific Gravity: Approximately 0.96
Percent Volatile: Negligible
Bulk Density: Approximately 7 pounds per gallon
10. Stability and Reactivity
Chemical Stability: Stable under normal conditions of storage and handling.
Conditions to Avoid: Avoid all possible sources of ignition (see Sections 5 and 7).
Incompatible Materials: Avoid contact with strong oxidizing agents.
Hazardous Decomposition Products: Combustion can yield major amounts of oxides of
carbon and minor amounts of oxides of sulfer and nitrogen.
74 |
Hazardous Polymerization: Will not occur.
11. Toxicological Information
No definitive information available on carcinogenicity, mutagenicity, target organs or
developmental toxicity.
12. Disposal Considerations
This material, if discarded as produced, is not a RCRA "listed" or "characteristic"
hazardous waste. Use which results in chemical or physical change or contamination may
subject it to hazardous waste regulations. Along with properly characterizing all waste
materials, consult state and local regulations regarding the proper disposal of this
material.
13. Transport Information
Hazard Class or Division: Not classified as hazardous
14. Regulatory Information
This material contains the following chemicals subject to the reporting requirements of
SARA 313 and 40 CFR 372:
---None--WARNING:
This material contains the following chemicals which are known to the State of California
to cause cancer, birth defects or other reproductive harm, and are subject to the
requirements of California Proposition 65 CA Health & Safety Code Section 25249.5)
---None Known--This material has not been identified as a carcinogen by NTP, IARC, or OSHA
EPA (CERCLA) Reportable Quantity:
---None---
75 |
15. Documentary Information
Issue Date: 11/24/2010
Product Code: SP-173
Previous Product Code: SP-173
16. Disclaimer of Expressed and Implied Warranties
The information in this document is believed to be correct as of the date issued.
HOWEVER, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR ANY PARTICULAR
PURPOSE, OR ANY OTHER WARRANTY IS EXPRESSED OR IS TO BE IMPLIED REGARDING
THE ACCURACY OR COMPLETENESS OF THIS INFORMATION, THE RESULTS TO BE
OBTAINED FROM THE USE OF THIS INFORMATION OR THE PRODUCT, THE SAFETY OF
THIS PRODUCT, OR THE HAZARDS RELATED TO ITS USE.
This information and product are furnished on the condition that the person receiving
them shall make his own determination as to the suitability of the product for his
particular purpose and on the condition that he assume the risk of his use thereof.
76 |
CHEMICAL-LABEL
77 |
Partners
PERSONAL PROTECTIVE EQUIPMENT (PPE)
1. EYE & FACE PROTECTION
ITEMS
1.
2.
3.
4.
YES
NO
PHOTO (EXAMPLE)
Safety Spectacles
Goggles
Face Shield
Others (please
verify)
……………………..
……………………..
…………………….
2. FOOT & LEG PROTECTION
ITEMS
78 |
YES
1.
Safety Shoes
2.
Others (please verify)
……………………..
……………………..
…………………….
NO
PHOTO (EXAMPLE)
2. ARM & HAND PROTECTION
ITEMS
YES
NO
PHOTO (EXAMPLE)
1. Safety Glove
2. Others (please
verify)
……………………..
……………………..
…………………….
3. BODY PROTECTION
ITEMS
79 |
YES
1.
Safety Apron
2.
Others (please
verify)
……………………..
……………………..
…………………….
NO
PHOTO (EXAMPLE)
References
Department of Environment. (December 2012). Cleaner Production towards Environment
Friendly Industries. Volume 2 (2).
Retrieved from http://cp.doe.gov.my/givc/wp-content/uploads/2014/01/CleanerProduction-vOL-2-nO-2-2012.pdf
Material Safety Data Sheet.
Retrieved from http://www.prochemical.com/MaterialSafety/Waxes/Batik%20Wax.pdf
Clean Batik Initiative - Manual for handling of chemical Substances Precautions and First
Aid. Retrieved from http://www.cleanbatik.com/assets/files/Chemical%20risks_final.pdf
Occupational Safety and Health Act (1994).
Retrieved from http://www.agc.gov.my/Akta/Vol.%2011/Act%20514.pdf
80 |
Lesson 5
Safe Workplace
Environment
81 |
Syllabus Outline
Objective
To instil good practices in promoting the importance of safe workplace environment amongst
local batik practitioners (both employers and employees).
Learning Assessment
Presentation and discussion on the importance of safe workplace environment.
Targeted Outcome
At the end of the session, participants will be able to share with employer/employees/colleagues
and be able to nurture safer workplace environment for cleaner batik SME.
Lesson topics
1. Introduction
2. Legislation / Acts related to Safe Workplace Environment in local and global context
3. Characterization of Safe Workplace Environment
82 |
Safe Workplace Environment
A.
Introduction
In this session, participants will now focus on another critical issue in batik making
industry; safe workplace environment which is often ignored/lacking on the ground.
Basically, employers in any business activity are held responsible for following factors:
a. ensuring the workplace health and safety of employees at work
b. providing systems of work that are safe and without risk to health
c. preventing occupational injuries and diseases
d. protecting the health and safety of others in relation to work activities, e.g.
visitors
Some of the highlights which will be addressed in this session include:
a. Important aspects of the workplace which will have an effect on workers;
b. Workplace – lighting, ventilation conditions
c. Workers – ergonomics, more comfort working conditions, such as simple mobilechair to ease movement during batik making processes.
d. Workers welfare – mini living room/rest & relax area, parking
e. Provision for firefighting – fire alarm, hose, fire extinguisher, etc.
f.
83 |
Posters– DO’s vs DON’Ts – Good vs Bad practices
Example:
Figure 5.5 Safety signage
B.
 Slides / notes
C.
Evaluation material
Evaluation of participants’ basic understanding on the importance of safe workplace
environment by using caption of actual batik workplace examples.
D.
84 |
References
Introduction
Objective
Learning Assessment
To instil good practices in promoting the
Presentation and discussion on the
importance of safe workplace
importance of safe workplace
environment amongst local batik
environment.
practitioners (both employers and
employees).
Targeted Outcome
will be able to share with employer
/employees /colleagues and be able to
nurture safer workplace environment
for cleaner batik SME.
85 |
Related Act & Regulations
 A national law of Malaysia, Occupational Safety and Health Act (1994) allows OSHA to
issue regulations for safety and health at workplace.
 7 regulations under OSHA (1994) to comply;

OSH (Safety and Health Policy)

OSH (Safety Officer) 1997

OSH (Safety and Health Committee) 1994

OSH (Classification, Packaging and Labeling of Hazardous Chemical) 1997

OSH Use And Standards Of Exposure Of Chemicals Hazardous To Health)
Regulations 2000

OSH (Control of Industrial Major Accident Hazard) Regulation 1996

OSH (Notification of Notification Of Accident, Dangerous Occurrence,
Occupational Poisoning And Occupational Disease) Regulations 2004.
86 |
Important to Highlight
Any employers of any business activities are held responsible for following items:
 ensuring the workplace health and safety of employees at work
 providing systems of work that are safe and without risk to health
 preventing occupational injuries and diseases
 protecting the health and safety of others in relation to work activities, e.g. visitors.
Characteristic of Good Workplace
 Workplace – GOOD lighting, ventilation conditions
 Workers – ergonomic, more comfort working condition such as simple mobile-chair to
ease the movement during batik making processes.
 Workers welfare – mini living room/rest & relax area, parking
 Provision for firefighting – fire alarm, hose, fire extinguisher etc.
87 |
Examples of Work Areas in Batik Industry:
Is This Safe?
88 |
How to Keep Safe and Healthy?
No
Current practice
GHK practice
1
Workers do not use Personal Protective
Provide Personal Protective Equipment (PPE).
Equipment (PPE).
2
89 |
Boiling Stage
3
Fixation Process
No
Current practice
CP practice
4
90 |
How to Keep Safe and Healthy?
References
Department of Occupational Safety & Health Malaysia, Ministry of Human Resources at
http://www.dosh.gov.my
Occupational Safety and Health Guide. Department of Environment Malaysia. Retrieved
from http://enviro.doe.gov.my
91 |
Lesson 6
Waste and
Residues
Management
92 |
Syllabus Outline
Objective
To introduce the basic concepts of ‘Waste and Residues Management’ including definitions of
waste, residues characteristics, and proper management of waste and residues.
Learning Assessment
Group discussion on best practices for batik making SME’s waste and residues management.
Targeted Outcome
Participants will be able to understand the basic concept of ‘Waste and Residues Management’,
which can later be applied at their factory.
Lesson topics
1. Introduction
a) Definition
b) Characteristics
2. Proper Waste and Residues Management
93 |
Waste and Residues Management
A.
Introduction
All waste or residual material generated from batik making processes must be
sustainably handled so as to create an environment-friendly workplace. Various attempts
have been made to transform the batik industry into a much more sustainable business,
such as the EU-SWITCH ASIA Program, as stated earlier in the introduction of this
module.
Waste is commonly defined as:
a) any discarded, rejected, abandoned, unwanted or surplus matter, whether or not
intended for sale or for recycling, reprocessing, recovery or purification by a
separate operation from that which produced the matter; or
b) anything declared by regulation or by an environment protection policy to be
waste,
whether of value or not.
Basically, waste can be divided into three categories – namely, solids, water, and air.
Table 5.1 shows examples for each category (attributed by batik making SMEs).
Table 5.1 Types of Waste and Examples
94 |
Type of waste
Example
Solid
Cloth patches, discarded materials such as used chemical containers, wax
Water
Wastewater – highly coloured
Air
Fumes from firewood burning during de-waxing process.
Fumes from hot molten wax vat.
Preparation of Cloth
Design & Canting
Color
Fixation (silicate)
Soaking
Residual Waste
Dewax
Rinse
Dry
Figure 5.1: Process flow in batik making which illustrates
sources of waste generation
The above illustration shows that we can manage residual matter at source with proper
residue management such as recovery at source, labelling, efficient combustion, better
ventilation, prevention (use as little water as possible), simple filtration system (to trap
wax particles that could not be recovered).
B.
Case studies
Case Studies on Wastewater and Solid Waste will be used in this session.
C.
 Slides / notes/ videos
95 |
D.
Evaluation material
Group Discussion on Best Practices for Residual Management.
E.
References
Introduction
Objective
Learning Assessment
To introduce the basic concepts of
Group discussion on best practices for
waste management including definitions
batik making SME’s waste and residues
of waste, waste characteristics, and
management.
proper management of wastes and
residues.
Targeted Outcome
Participants will be able to understand
the basic concept of waste and residues
management, in turn with that
knowledge; later can be applied for their
SME at home.
96 |
Definition
 Waste

any discarded, rejected, abandoned, unwanted or
surplus matter, whether or not intended for sale or for
recycling, reprocessing, recovery or purification by a
separate operation from that which produced the
matter; or

anything declared by regulation or by an environment
protection policy to be waste,
 Residual;

OSH remaining/unused/leftover after the greater part
or quantity has gone
97 |
Hotspot to Manage?
98 |
cloth
design
color
soaking
Color
fixation
Dewax
Rinse
Dry
Case Studies:
Does This Happen At Your Workplace?
99 |
Case Studies:
100 |
Case Studies:
 Resource recovery,
 Prevention (use as minimum of water as possible),
 Simple filtration system (to trap wax particles that could not be recovered)
 Warning signage,
 Efficient combustion,
 Better ventilation for storage area,
How Do You Treat Waste Water?
Activated carbon waste water treatment from http://teknikalkraf.blogspot.com/2012/04/
101 |
References
Rashidi, H, R., Nik Sulaiman, N, M., Hashim, N, A. (2012). Batik industry synthetic
wastewater treatment using nanofiltration membrane. Journal of Procedia Engineering,
44, 2010 – 2012.
Case Studies on Residual Use and Energy
Retrieved from www.nrel.gov/docs/legosti/old/7974.pdf
Studies of Residual Management in Industry
Retrieved from www.nber.org/chapters/c2838.pdf
102 |
Lesson 7
Energy
Management
103 |
Syllabus Outline
Objective
To share appropriate and strategic tools in promoting sustainable energy management in batik
making processes (both employers and employees).
Learning Assessment
Discussion and reflection on the importance of applying appropriate tools in managing energy
more sustainably.
Targeted Outcome
At the end of the session, participant will be able to: identify and applying appropriate tools on
energy management that suit their working environment, which could vary from one SME to
another.
Lesson topics
1. Introduction
2. Identification and classification of energy usage in local batik industry
104 |
Energy Management
A.
Introduction
In this session, participants are required to understand the importance of energy
management on a day-to-day basis. Some of the scenarios and appropriate tools (which
may not necessarily be in the form of technology) will be pointed out in this session,
including:
 Use of energy in utilities such as:

Lighting system –

Running of equipment – washing machine, pumps, ironing process
 Use of energy for heating purposes such as:

Dewaxing activity where wax is removed by boiling – in this case, the
common fuels may be firewood or natural gas.
 Safety issues connected with the use of electrical equipment

Safety issues – if a short-circuit ever occurs, proper handling of the
situation should be addressed appropriately.
 Tools to manage energy in a sustainable manner
•
Wherever or whenever groundwater is utilized in the batik making
process, the usage of the pump must be monitored – to reduce energy
consumption.
•
Sky-lighting method should be adopted as an alternative to reduce
electricity consumption on lighting.
•
Firewood must be stored in a dry area or an air blower used to help
make combustion more efficient.
This session will be able to promote energy-efficient work practices for those involved in
batik making SME.
105 |
B.
 Slides / notes
C.
Evaluation material
Group Discussion.
D.
106 |
References
Introduction
Objective
Learning Assessment
To share appropriate and strategic tools
Discussion and reflection on the
in promoting sustainable energy
importance of applying appropriate
management in batik making processes
tools in managing energy more
(both employers and employees).
sustainably.
Targeted Outcome
At the end of the session, participant
will be able to: identify and applying
appropriate tools on energy
management that suit their working
environment which could be varied
from one SME to another.
107 |
Energy Usage in Batik Industry
 Usage of energy as utilities such as:

Lighting system –

Running of equipment – washing machine, pumps, ironing process
 Usage of energy for heating purposes such as:

Dewaxing activity where wax is removed by boiling – in this case,
the common fuels maybe firewood or natural gas.
How to Manage Energy Usage?
 If groundwater is utilized wherever or whenever in batik making process,
the usage of pump must be monitored – to reduce energy consumption.
 Sky-lighting method should be adopted as alternative to reduce electricity
consumption on lighting.
 Firewood must be stored in dry area or use air blower to help combustion to
be more efficient.
108 |
CP - Energy Saving Practice
Installation of blower to reduce energy consumption
The principle of using "blower" to the boiling process:
The burning process is more effective - supply air which contains oxygen into the combustion chamber.
The efficiency of combustion process will increase 50%
(based on the use of blowers in Indonesia)
109 |
References
Capehart, B. R., Turner, W. C., & Kennedy, W. J., (2011). Guide to Energy Management.
Farimont Press.
Doty, S. & Turner, W. C. (2012). Energy Management Handbook. Fairmont Press
110 |
Lesson 8
Inventory
Management
111 |
Syllabus Outline
Objective
To promote the importance of inventory management / good housekeeping practices for local
batik practitioners towards cleaner batik production for SME.
Learning Assessment
Discussion on the basic inventory management skills that suits the batik making industry.
Targeted Outcome
Participants will be able to practice good inventory management at their workplace, and will be
able to transfer acquired knowledge to their respective counterparts.
Lesson topics
1. Introduction
2. Inventory Management
3. Good Housekeeping practices
112 |
Inventory Management
A.
Introduction
In this session, participants will be introduced on the basic concept of inventory
management which is part of supply chain management; vital for any business entity. It is
primarily about specifying the size and placement of stocked goods required at different
locations within a facility or within multiple locations of a supply network to protect the
regular and planned course of production against the random disturbance of running out
of materials or goods. Some of the highlights in this session include:
a. Inventories of raw material coming in and going out: FIFO (First In, First Out)
including cloth and chemicals
b. Inventory Product Output: batik
c. Inventory utilities – water and electricity consumption
d. Catalogue of design
e. Record of workers - attendance, wages, working hours
Good housekeeping practices within the batik industry will improve efficient use of
resources and workplace safety for workers.
B.
Slides / Notes – how to use simple software to store/catalogue designs in digital form.
C.
Evaluation material
 Group Discussion on inventory management for batik making SME
 Mock-up Checklist for inventory management
D.
113 |
References
Introduction
Objective
Learning Assessment
To promote the importance of inventory
Discussion on the basic inventory
management / good housekeeping
management skills that suits the batik
practices for local batik practitioners
making industry.
towards cleaner batik production for
SME.
Targeted Outcome
Participants will be able to practice good
inventory management at their
workplace, and will be able to transfer
acquired knowledge to their respective
counterparts.
114 |
What is Inventory?
 A complete list of items such as property, goods in stock, or the contents of
a building
 List for batik industry:
Raw Material
Product
Workers
Utilities
Cloth
Batik sarung
Attendance
Water
Chemical
Kaftan
Health record
Electricity
Dyes
Kain ela
Wax
What is Inventory?
 Reduce risk of losses
 Make effective use of working capital
 Avoid duplication in ordering stock
 Minimize administrative workload
 Facilitate cost accounting activities
 Check loses of materials due to pilferage
115 |
How to Manage?
 If Must have logbooks

Logbook 1 : Raw materials Inventory

Logbook 2 : Utility monthly bill

Logbook 3 : Product record

Logbook 4 : Worker’s record
 Must record
 Check / Analyze
 Correction and Improvement
Good Housekeeping Practices
 Proper signage
 General cleaning/maintenance
 Proper storage
116 |
COMPANY INFORMATION
TRANSFORMATION OF BATIK SMEs TOWARDS
SUSTAINABILITY THROUGH CLEANER PRODUCTION
PRACTICE
COMPANY INFORMATION
Company Name :
Type: Stamp / Chanting / Screen
Year of establish :
Address :
Tel :
Fax :
Website (if any):
Email :
Contact Person / Position :
HP :
Number of permanent workers:
Number of contract workers:
Premise size (m2) :
Types of product :
Types of dyes :Natural / Syhtnethic
Water sources : (Undergorund / river / Water Agency)
Energy usage : (Electricity / firewood fuel/ etc)
Production capacity per month:
Constraints (3 importants):
Future plan for improvement:
117 |
Partners
Funded
INVENTORY CHECKLIST
ITEMS
1.
YES
NO
RAW MATERIAL
CLOTH
DYES
SODIUM SILICATE
WAX
FIREWOOD
2.
PRODUCT
BATIK SARUNG
KAFTAN
KAIN ELA
3.
WORKERS
ATTENDANCE
HEALTH RECORD
4.
UTILITIES
ELECTRICITY BILL
WATER
118 |
Partners
Funded
INVENTORY FORM
NAME: ______________________________________________________________________
COMPANY: ___________________________________________________________________
ITEM: _______________________________________________________________________
DATE
119 |
IN
(pcs)
OUT
(pcs)
BALANCE
(pcs)
SIGNATURE
WATER
Resources Quantification
Company name:__________________________________________________________
A. Water
No
Proces
1
2
3
4
Quantity of usage
m3/L
Quantity of
wastage
m3/L
Coloring
Fixation
Soaking
Rinsing
Total per month
No
hotspot
Total per month
120 |
ENERGY
Company name:__________________________________________________________
B. Energy
no
Process
Equipment
Quantity
gas (kg)
Total usage
firewood
fuel (liter)
(kg)
Total per month
121 |
Electricity
(kwh)
MATERIALS
Company name:__________________________________________________________
C. Raw material
No
122 |
Material
Types
Quanitity/month
Unit
Quantity.year
Unit
HOTSPOT
Company name:__________________________________________________________
D. Hotspot
No
Hotspot
Wastage
Quantity
Unit
Measurement
* monthly
123 |
WORKERS ATTENDANCE
Company name:__________________________________________________________
E. workers attendance
Name:___________________________________________________________________
Month/Year:
No
124 |
Day
Time (in)
Time (out)
Sign
WORKERS HEALTH RECORD
Company name:__________________________________________________________
F. workers health record
Month/Year:
No
125 |
Name
Total of days
away
Reasons
References
Inventory Management at http://www.managementstudyguide.com/
Freeland, J. R. (1991) Harvard Business Review - Case: Managing Inventories.
Darden School of Business.
Hairuddin, H., Md. Noor, N, L., & Ab. Mali, A. (2012). Why do microenterprise refuse to
use Information Technology: A case study of Batik Microenterprise in Malaysia.
Journal of Procedia Social and Behavioural Science, 57, 494 – 502.
Nordin, R. & Abu Bakar, S, S. (2012). Malaysian batik industry: Protecting local batik
design by copyright and industrial laws. International Journal of Business and
Society, 13(2), 117 – 132
126 |
Lesson 9
Site Visit
127 |
Syllabus Outline
Objective
To expose participants to the good management practices of selected batik producers.
Learning Assessment
Individual or group assignment.
Targeted Outcome
At the end of the session, participants will be able to enhance their understanding of a cleaner
production approach through in situ practical lessons and hands-on training.
Lesson topics
1. Site visit
128 |
Site visit
A.
Introduction
Site visit provides participants the opportunity to meet and discuss with a selected, good
practice batik producer. In addition, such a visit also allows participants to experience
and familiarise themselves with the daily operations of the selected workplace. Site visit
is a good platform where participants will be able to relate to or practise everything they
learnt during previous theoretical sessions.
B.
Case studies
Hands-on lessons on good batik making practices.
C.
129 |
i.
Hotspot form
ii.
Eco-map
iii.
Root cause analysis
iv.
Development of cleaner production option.
Introduction
Objective
Learning Assessment
To expose participants to good
Individual or group assignment
management practice of selected batik
producers.
Targeted Outcome
will be able to enhance their
understanding on Cleaner Production
approach through in situ practical
lessons and hands-on training.
Summary
Each participants will be asked to share their observation and feedback among
themselves especially on best management practices (include cleaner
production) that could help them.
130 |
FORM 9.1: ECO-MAPPING FORM
NAME:
DATE:
COMPANY:
131 |
FORM 9.2: ROOT CAUSE ANALYSIS
NAME:
DATE:
COMPANY:
To complete root cause analysis, you will need:
 Eco-Map;
 List of Hotspots
No.
Root cause to be
improved:
1
2
3
4
132 |
Lesson 10
Towards
Eco-Labelling/
Certification
133 |
Syllabus Outline
Objective
To introduce and to promote eco-labelling / certification and its importance for batik making
SMEs and local practitioners.
Learning Assessment
Group Discussion.
Targeted Outcome
At the end of the session, participants will have a better understanding on the importance of ecolabelling / certification to their batik making SMEs.
Lesson topics
1. Introduction
2. Benefits of Eco-Labelling / Certification
3. Methods in Applying for Eco-Labelling / Certification
134 |
Importance of Eco-Labelling/Certification
A.
Introduction
This session serves to introduce eco-labelling/certification to local batik practitioners. In
general, Eco-labelling can be explained as a mean in communicating a product
environmental benefits to consumers and businesses.
In Malaysia, Standards and Industrial Research Institute of Malaysia (SIRIM Berhad), is a
corporate organisation owned wholly by the Malaysian Government, under the Minister
of Finance Incorporated. Hence, SIRIM introduced a scheme namely SIRIM QAS
International Eco-labelling Scheme, on which a product will be independently tested and
verified before the organisation is allowed to use SIRIM QA Eco-Labelling mark on its
product, packaging and materials. Eco-Labelling mark is used as marketing tool which will
enable a company to position its product as an environmentally-friendly product. This, in
turn, will give the product a competitive edge over other similar products in a consumer
market that is increasingly becoming more environmentally conscious.
Types of Eco-Labelling/Certification (according
to SIRIM):
1) Environmental Labelling Programme [ISO 14024]: Certification with criteria to
determine the quality of a product, which will be certified by third party.
2) Environmental Labelling Programme [ISO 14021]: Self-declaration on targeted
environmental aspect of a product.
3) Environmental Labelling Programme [ISO 14025]: Disclosure of quantitative
information but inclusive of amount of environmental burden of a product, all
data will be verified by third party.
B.
Benefits of Eco-labelling/Certification
1) Increase marketability of products to environmentally conscious consumers.
135 |
2) Help improve company’s brand image as an organisation that produces
environmentally- friendly products.
3) Help increase competitiveness where purchasing decision is based on
environmental attributes.
C.
Methods of Applying for EcoLabelling/Certification
D.
 Slides / notes/ videos
E.
Evaluation material
Group Discussion
To allow participants to share opinions and suggestions on eco-labelling/certification
F.
136 |
References
Definition of Eco-Labelling
(Materials derived from SIRIM)
Ecolabelling - Communicating a product environmental benefits to
consumers and businesses.
SIRIM QAS International Eco-labelling Scheme product will be
independently tested and verified aga before the organisation is allowed to
use SIRIM QA Eco- Labelling mark on its product, packaging and p materials.
Eco-Labelling mark - Marketing tool which will enable a company to
position its product as an environmentally-friendly product. This, in turn,
will give the product a competitive edge over other similar products in a
consumer market that is increasingly becoming more environmentally
conscious.
Eco-Labelling: Benefits
 Slides Increase marketability of products to environmentally conscious consumers
 Help improve company’s brand image as an organisation that produces
environmentally- friendly products.
 Help increase competitiveness where purchasing decision is based on environmental
attributes.
137 |
Eco-Labelling: Benefits
138 |
Method: Applying for
Eco-Labelling/Certification
139 |
PRODUCT CRITERIA CURRENTLY AVAILABLE FOR THE
SIRIM QAS INTERNATIONAL ECO-LABELLING SCHEME
A
MALAYSIAN STANDARD
1
MS 2073:2008
ECO-LABELLING CRITERIA FOR ENVIRONMENTALLY DEGRADABLE
PLASTICS PACKAGING MATERIAL
2
MS 2080:2008
ECO-LABELLING CRITERIA FOR RECYCLED PAPER
3
MS 2225:2009
ECO-LABELLING CRITERIA FOR BIODEGRADABLE CLEANING AGENTS
4
MS 2237:2009
ECO-LABELLING CRITERIA FOR ELECTRIC & ELECTRONIC
EQUIPMENT & COMPONENTS WITH RESTRICTED HAZARDOUS
SUBSTANCES
5
MS 2454:2012
ECO-LABELLING CRITERIA FOR PAPER-BASED PACKAGING PRODUCTS
6
MS 2456: 2012
ECO-LABELLING CRITERIA FOR BIOFIBRE POLYMER COMPOSITES – CONSTRUCTION
APPLICATIONS
B
SIRIM ECO-LABELLING CRITERIAS
1
ECO 1- ENVIRONMENTALLY DEGRADABLE & NON-TOXIC PLASTIC PACKAGING MATERIAL.
(UPGRADED TO MS 2073:2008)
140 |
2
ECO 2 - HAZARDOUS METAL-FREE ELECTRICAL AND ELECTRONIC EQUIPMENT &PARTS
3
ECO 3 - BIODEGRADABLE CLEANING AGENTS
4
ECO 4 - RECYCLED PAPER
5
ECO 5 - BIOFIBRE COMPOSITE CONSTRUCTION MATERIAL
6
ECO 6 - FOOD-GRADE LUBRICANTS
7
ECO 7 - FLOOR MAT
8
ECO 8 - FABRIC CARE PRODUCT
9
ECO 9 - TABLEWARE FROM BIOMASS
10
ECO 10 - ADHESIVES
11
ECO 11 - WATER-BASED ADHESIVES
12
ECO 12 - PAPER-BASED PACKAGING PRODUCTS
141 |
13
ECO 13 - ORGANIC FERTILIZER
14
ECO 14 - RECYCLED RUBBER PRODUCTS
15
ECO 15 - SHAMPOO PRODUCTS
16
ECO 16 - SHOWER LIQUID PRODUCTS
17
ECO 17 - SOLID BODY SOAP PRODUCTS
18
ECO 18 - RECYCLED PLASTIC PRODUCTS
19
ECO 19 - PAINTS
20
ECO 20 - CLAY ROOF TILES
21
ECO 21 - FIBRE CEMENT PRODUCTS
22
ECO 22 - CERAMIC TILES
23
ECO 23 - MASONRY UNITS
24
ECO 24 - ENERGY SAVING ELECTRONIC BALLASTS
25
ECO 25 - FLUORESCENT LAMP
26
ECO 26 - PRINTING INK
27
ECO 27 - LUMINAIRES AND LIGHT SOURCE FOR INTERIOR LIGHTINGS
28
ECO 28 - PAPER PRINTED MATERIAL
29
ECO 29 - CEMENT
30
ECO 30 - BALLPOINT PEN
31
ECO 31 - FLAT GLASS PRODUCTS
32
ECO 32 - COATED FLAT STEEL PRODUCTS
33
ECO 33 - CONCRETE ROOFING TILES
34
ECO 34 - APPAREL AND TEXTILE PRODUCTS FROM NATURAL FIBERS
35
ECO 35 - CARPET
36
ECO 36 - BIOMASS PELLET AND BRIQUETTE
37
ECO 37 - SOLAR WATER HEATER SYSTEM
References
SIRIM Berhad
Retrieved from http://www.sirim.my/
SIRIM QAS International Sdn. Bhd.
Retrieved from http://www.sirim-qas.com.my/
142 |
Lesson 11
Wrap-Up and
Evaluation
143 |
Syllabus Outline
Objective
To summarise the training session.
Learning Assessment
Discussion, individual assignment (exit survey & feedback form), action plan.
Targeted Outcome
At the end of the session, participants’ survey, feedback and ideas will be compiled and analysed.
Lesson topics
1. Introduction
2. Wrap-up
3. Exit survey and Feedback Form
4. Action Plan
144 |
Importance of Eco-Labelling/Certification
A.
Introduction
This session acts as the finale of the module/training. During wrap-up session,
participants will be given exit survey and feedback form to be completed and returned to
the trainers.
Green practices are implemented as preventive measure to save unnecessary costs
through efficient resource, energy, and water consumption. Besides practising workplace
safety, the reduction of waste and residues is also one of the cost-cutting practices.
Furthermore, the ways towards environment protection can be improved.
B.
 Slides / notes
C.
Evaluation material
a.
Exit survey
To determine participants’ level of knowledge on cleaner production after
training.
b.
Feedback form
To obtain participants’ view, feedback, and recommendations which are
important for this module’s improvement or to be used for the next training
sessions.
c.
Action plan
To enable participants to come out with their strategy to improve their
workplace.
145 |
Introduction
Objective
Learning Assessment
To summarise the training session.
Discussion, Individual assignment (exit
survey & feedback form), action plan.
Targeted Outcome
At the end of the session, participants’
survey, feedback and idea will be
compiled and analysed.
146 |
Guideline Info Notes:
Participant
Each participants will be asked to complete following items:
Exit survey: to determine participants’ level of knowledge on cleaner production
after training.
Feedback form: to obtain participants’ view, feedback, and recommendations
which are important for this module’s improvement or to be used for the next training
sessions.
Action plan: to enable participants to come out with their strategy to improve their
workplace.
147 |
F11.1 EXIT SURVEY
PRACTICE
DATE
:
NAME
:
COMPANY
:
ADDRESS
:
CONTACT NO
:
Please use the prescribed scale to rate the level of your proficiency in the listed Programme Outcomes at
TIME OF EXIT to the programme.
Rating
0
1
2
3
4
5
Level of
proficiency
None
Poor
Fair
Average
Good
Excellent
Ratings
Outcomes
Items
0
1. Build deeper
understanding on
the basic concept of
cleaner batik
production
a) I can describe what is clean batik production
or the application
cleaner production
approach
a) I can explain the application of cleaner
production
which can go for
eco-labelling
certification
a) I am able apply the knowledge for a better
production process for eco-labelling
certification
1
2
3
4
b) I am able to explain the concept of clean
production
c) I can explain why clean production is crucial
b) I am able to apply the cleaner production
approach in my current production
b) I am able to produce eco-batik products in
compliant with eco-labelling certification
Other comments:
Thank you. This survey will help us to better understand your needs for the continual
improvement of the quality of future programmes.
148 |
5
F11.2 PROGRAMME FEEDBACK FORM
PRACTICE
Dear participants,
Thank you for your attendance. We would appreciate if you could spend a little time to complete
the following assessment. Your views and suggestions are of great value to us to improve our
services in the future. Thank you.
Rating System is as follows:
(1) Poor
(2) Average
(3) Satisfactory (4) Good
(5) Excellent
1. Overall Rating:
Element:
Rate:
Speakers & Presentation
Venue suitability
Time allocation
Food
Programme content
Your knowledge understanding from programme
Overall rating of the programme
2. Suggestions / views / comments for the future:
…………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………
149 |
FundedFunded
Partners
LESSON 11: ACTION PLAN
NAME
_______________________________________________
COMPANY
_______________________________________________
DATE
_______________________________________________
#
1
Hotspot
ROOT CAUSE
TO BE
IMPROVED:
ACTION
PLAN
COST-BASED:
YES / NO
BENEFITS
Hotspots:
 ECONOMY
Note:
 ENVIRONMENT
 SAFETY
2
Hotspots:
 ECONOMY
Note:
 ENVIRONMENT
 SAFETY
150 |
3
Hotspots:
 ECONOMY
Note:
 ENVIRONMENT
 SAFETY
4
Hotspots:
 ECONOMY
Note:
 ENVIRONMENT
 SAFETY
5
Hotspots:
 ECONOMY
Note:
 ENVIRONMENT
 SAFETY
151 |

Transformation of Batik Small and Medium Enterprises (SMEs

Transcription

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