WONKA INDUSTRIES PLANT SAFETY

Wonka Industries
Plant Safety in Factory
George Harmon
07-23-2015

WONKA INDUSTRIES PLANT SAFETY

Table of Content
Executive Summary ... 3
Introduction 4
Research Methods .. 5
Results ..... 6
Conclusions ..... 8
Recommendation 9
Annotated Bibliography .... 10
References ... 11
Appendix A . 12
Appendix B . 13

WONKA INDUSTRIES PLANT SAFETY

Executive Summary
The purpose of the study is for clarifying information concerning plant safety at Wonka
Chocolate Factory: Todays safety standards introduced a functional safety management system
which created a series of work processes established on top of the traditional quality
management system. The FSM system requires documenting the risk reduction requirements and
corresponding validation testing to demonstrate that the risk reduction was achieved.
To perform these tasks, we performed guidelines such as: wearing a life jacket when
coming aboard onto a dock. A railing is needed in place as well, when these children are not
wearing a life jacket ; this is more at risk for them to drown when they fall are even death.
Because of the hurt workers retrieving children from the extraction pipe; engineers states, That
they lowered a contraption with three plastic pipes down a metal cable. The results were to jam
those pipes into the lake bottom and pull up plugs of mud.
Wonka Industries warehouse can be a dangerous place. When it comes to protecting
people on a daily basis, a yellow line painted on the floor does not stop accidents from
happening. The whole plant or warehouse is a workplace, and even the most automated conveyor
system needs safe access. The safety department, the training department and plant layout need
to be involved. Separating and defining work areas and walkways as well as providing drop-off
protection for interior loading and rail docks has long been a challenge in industrial plants and
facilities. Conducting a pedestrian safety assessment can reveal all areas that need improvement.
Our findings suggest that employees and customers first step in the safety hazard is to
understand the hazards and the risk (see Appendix B). On the basis of these findings, we
recommend that plant safety at Wonka Chocolate Factory proceed with its risk reduction
requirements and corresponding validation testing to demonstrate the risk reduction, and to use
the products from A-Safe to prevent future accidents.

WONKA INDUSTRIES PLANT SAFETY

Introduction
Safety pays for everyone, the cost of injury prevention is far less than the cost of an
injury. A safe and healthy workplace attracts and retains quality employees. Its an asset to a
community, operates more efficiently and enjoys a healthy bottom line. The business and the
workers thrive in a safe, healthy, respectful and caring environment. Hazards exist in every
workplace in many different forms: The Occupation Safety and health Administration (OSHA)
require that employers protect their employees from workplace hazards that can cause injury.
Over the past year we have had numerous accidents occur to both employees and
customers who toured the factory. 4 children have fallen into Chocolate River during the tour; 3
fell into the river from the dock and one fell from the boat. Oompa Loompa factory workers
have hurt themselves retrieving children form chocolate extraction pipe that runs form the river
to the fudge room. This research paper will explain the benefits of using A-Safe products.

WONKA INDUSTRIES PLANT SAFETY

Research Methods

Wonka Industries workmans compensation insurance rates have increased 50%.

According to a study by OSHA (AmaxxWorkersCompExperts, 2012), the hidden cost of a
Workers compensation claim is 4.5 times the direct cost (the medical and indemnity benefits).
Other studies place the hidden cost as low as 3 times the direct cost and as high as 10 times the
direct cost. Hidden cost of a worker compensation claim can be significantly reduced through a
safety program. These are only financial costs. Theres no way to know the value of the quality
of life lost to injuries. A safe and healthy workplace not only protects worker from injury, it can
also lower injury costs, reduce absenteeism and turnover, increase productivity and quality, and
raise employee morale. In other words, safety is good for business. Plus, protecting worker is
the right thing to do.
Pedestrian Safety: We can never discuss pedestrian and vehicle safety too much. Over the
past year Oompa Loompa factory workers have hurt themselves retrieving children from
chocolate extraction pipe that runs from the river to the fudge room which had cost Oompa
Loompas to lose over 200 hours of productivity annually. The most important point to stress is
not to take shortcuts. Stay on the cross walk and out of the no pedestrian areas. The pedestrian
safety walkways have to be setup by using different types of barriers, hand railing, and gates.
The researcher team tested several brands of barriers, hand railings, and swing gates to
separate people from hazardous areas. The companies products researched were from Rite-Hite
who designs barrier products to protect your employees and equipment in any environment
(Rite-Hite, 2015); FS Industries; and A-SAFE.

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Results

After careful researching and finding solutions to children falling and workers hurting
themselves from retrieving children from the Chocolate River, dock and the boat. The following
proposal results can be used to prevent further injuries are from A-Safe:
Pedestrian Barrier. The most popular item in the pedestrian segregation range and one
of our most sought-after products. Pedestrian Fencing Safety Barriers are the perfect option for
clearly defining pedestrian walkways, ensuring that people on foot are safe. The plastic safety
barriers don't allow people to stray in to vehicle areas because they create a physical barrier to
ensure safe segregation between people and lighter vehicles. A-Safes Pedestrian Barriers helps
minimize crossing points throughout your environment and gates can be incorporated in to the
modular and flexible system. If needed, safety signs can also be mounted to the product for extra
protection.
Hand Rail. Our Hand Rail is a lightweight system and an ideal choice for areas of the
workplace where there is a risk of falling. The A-SAFE Hand Rail is a great option for areas
where segregating people from dangerous equipment is crucial, and it helps to prevent many
other potential risks. The rails clearly mark out the pedestrian pathway and act as a physical
barrier, ensuring visitors and personnel do not accidentally stray into potentially dangerous
areas. The modular Hand Rail is highly visible to help vehicle operators see a boundary and it
clearly defines two separate areas for pedestrians and vehicles. Extras such as swing gates, slide
gates, sign boards and kick plates can be easily added.
Swing Gate. Swing Gates are used as access and exit points for pedestrians. They
are mainly used alongside A-SAFE Pedestrian Barriers, but can be compatible with most barrier
systems or can also be used as a stand-alone gate. They are ideal for pedestrian access and are

WONKA INDUSTRIES PLANT SAFETY

available in a safety green color as well as in the standard A-SAFE yellow and black. The gates
have a single swing action and are provided with a gate stop. Manufactured to swing inwards to
ensure that the movement of a pedestrian is checked before they enter a traffic area. Swing Gates
come with yellow and black rails to assist with a clean appearance and to ensure they are easily
identifiable within a run of Pedestrian Barriers. The safety green gates indicate access points for
fire exits, fire or safety equipment or medical assistance.

WONKA INDUSTRIES PLANT SAFETY

Conclusions
A-Safe are the inventors and manufacturers of fixed polymer safety barriers; used around
the world to offer unbeatable, money-saving protection for buildings, personnel and equipment.
They have over 30 years' experience in plastic extrusion, and in that time have grown in to a
world leader in workplace safety solutions. They are a worldwide brand, chosen by some of the
best companies in the world, and offer you the best in safety, advice, consultation and aftercare.
The Willy Wonka Candy Company is a brand of candy owned by and license by Nestle
(Wikipedia, 2014). Willie Wonka may have locked the world out of his chocolate factory, but
real-world chocolate companies have to let inspectors in. Like any food product, rules for
producing and handling chocolate are set by the Food and Drug Administration. The production
of chocolate candy can involve many steps, and each step introduces more risk of contamination.
Every stage of chocolate production must have adequate safety protocols in place.
Pedestrian as well as employees need to be safe, therefore, boundaries need to be setup.
The below list are some of the safety guideline that has been implemented at Wonka Industries
(Sweet Candy, n.d.).

We require that you have one adult chaperone for every seven (7) children
Everyone must wear a hair net, we will provide these free when the tourist arrives
There will be yellow lines marking the tour path on the factory floor.
A-SAFE Railing will surround all potential hazardous areas
As far as children falling in the Chocolate River, A-SAFE has installed a locking
device for its swing barrier for entry and exiting the boat, and also a pedestrian
barrier around the entire boat.

WONKA INDUSTRIES PLANT SAFETY

Recommendations
The problem states that children have fell into a river causing death and being injured
employers has also gotten injured as well. The fact of the matter is to make sure proper railing is
on docks once anyone come aboard. No child should be left behind without supervision when
taking a tour. Insecurity has caused the company lots of money and workers compensation rates
have increased 50%.
Even the investigators have cost workers a large portion of money. Every tour should be
treated as a risk hazard, because accidents do occur when you least expect them to. With the
extraction pipe running from the river to the fudge room there should be something in range to
separate the fudge room when the pipe runs into the river.
To avoid further injury or even death, I recommend that we used A-Safe products such as
their pedestrian barriers, hand railing, and swinging gate. A-Safe provides innovative and awardwinning safety barriers and advice, helping workplaces like Wonka Industries to adjust and
adhere to new Health & Safety obligations. Image of their products can be found in Appendix A.

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Annotated Bibliography
To inform the readers I would like to say I have gathered my sources from these
different sites on hazardous on a work site and safety. It goes on in depth stating that these
sources have been retrieved and is a guide to be used from different sites. There are other
websites and sources that I didnt list, but also have more additional and interesting information.
These sites also give you the results of the proper and effective way of doing things on a job.
These sources give guidelines to follow and many different kinds of research like gene
wilder, playing Willy Wonka explained, the Oompa Loompa were people who Wonka took from
their native land, supposedly to protect them and housed the in his factory where they worked
diligent for him. If you observe these sources the web address gives you exactly what the title is
going to be about. The owner of this factory is Mr. Willy Wonka, he feels the mystery workers
operating his factory after the re-opening are called Oompa Loompa. He faces the new
challenges and mysteries of the factory with the save bravery he employs to overcome the
adversity of his everyday life.

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References
AmaxxWorkersCompExperts. (31 August, 2012). The hidden cost of workers compensation.
Retrieved from http://reduceyourworkerscomp.com/hidden-cost-of-workers-comp/.
FEMA. (2015, March 19). Threat and Hazard Identification and Risk Assessment. Retrieved
from http://www.fema.gov/threat-and-hazard-identification-and-risk-assessment.
Rite-Hite. 2015. Rite-hite always looking ahead. Retrieved from
http://www.ritehite.com/en/AM/About-Us.
Sweet Candy Company. (n.d.). Sweet candy company factory tour guidelines. Retrieved from
http://www.sweetcandy.com/site-media/docs/Sweet_Tour_Guidelines_old.pdf.

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APPENDIX A

Pedestrian Barrier

Hand Rail

Swing Gate

WONKA INDUSTRIES PLANT SAFETY

APPENDIX B

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