Manufacturing HSE Gemba RADAR (Risk Awareness, Detection, Action, Review)

• Conducted on

  Date
• Plant Location
  Address
• Department
  Address

• Manufacturing Cell or line reference

• Conducted by

  Sign

Manning

• Are employees wearing the correct personal protective equipment (PPE)? (Check shoes, workwear, hands, arms, eyes and face. Do they need to wear any respiratory protection. Check if they have long hair that requires a hair net or wearing jewellery that may get entangled)?)

  Yes

  No

  N/A

• Ask why not?

• Is the PPE in satisfactory condition and stored appropriately when not in use?

  Yes

  No

  N/A

• Is the PPE used fit for its intended purpose?

  Yes

  No

  N/A

• What is the issue?

  Media

• Has the employee received sufficient training to carry out the task/work? Ask the employee

  Yes

  No

  N/A

• What additional training is needed?

Machine

• Are fixed guards in place as installed? (check for disconnected or removed guards)

  Yes

  No

  N/A

• Are all installed safety devices in working order? (interlocked doors/gates/fences, light curtains, sensors etc)

  YES - All in working order

  NO

  Partial - Some not Functional

  N/A

• Identify and Report to maintenance and plan action to rectify. Ensure immediate safety of employee is not compromised

  Media

• Are all control panels closed and locked? (check if the panel is able to be locked for lock out tag out purposes)

  YES - All in working order

  NO

  Partial - Some not Functional

  N/A

• Identify and Report to maintenance and plan action to rectify. Ensure immediate safety of employee is not compromised

  Media

• Are all control panels in good working order? (look for broken or missing controls or gauges etc)

  YES - All in working order

  NO

  Partial - Some not Functional

  N/A

• Identify and Report to maintenance and plan action to rectify. Ensure immediate safety of employee is not compromised

  Media

• Can the equipment be put into a safe state and locked out to perform intrusive activities? (e.g. maintenance, changeover, blockage etc)

  Yes

  No

  N/A

Materials - Look and talk to the employee(s)

• Are there any chemicals / chemical hazards in the cell?

  Yes

  No

  N/A

• Are they stored in suitable cabinets and dispensed in suitable containers?

  Yes

  No

  N/A

• Identify the issue

  Media

• Are all chemical containers correctly labelled? (Refer GHS for chemical labelling and identification)

  Compliant

  Non-Compliant

  N/A

• Remove from area and replace.

  Media

• Are hand tools being used for routine adjustment/correction?

  Yes

  No

  N/A

• Are the hand tools fit for purpose? (i.e. are they proprietary and NOT home made/temporary)

  Yes

  No

  N/A

• Arrange to remove from the cell and replace

  Media

• Are the hand tools in suitable condition for use? (i.e. not worn or broken)

  Good

  Fair

  Poor

  N/A

• Arrange to remove from cell and replace

  Media

Methods - Talk to the employee(s)

• Is the employee required to perform any significant lifting and manual handling of materials or products?

  Yes

  No

  N/A

• What is the issue?

  Media

• Is the employee performing any repetitive motions that may cause upper limb disorders?

  Yes

  No

  N/A

• What is the issue?

  Media

• Is the employee expected to enter potentially dangerous or hazardous parts of the equipment without the machine being in a stopped, safe condition? Ask the employee

  Safe

  At Risk

  N/A

• What is the issue?

  Media

Environment - Look, Feel and Listen

• Is the lighting sufficient to carry out the tasks?

  Good

  Fair

  Poor

  N/A

• Is the area too hot or too cold? (ask the employee)

• Are the noise levels higher than 80 dBA? (e.g. Do you have to raise your voice to be heard)

  Yes

  No

  N/A

• Is the operator wearing suitable hearing protection?

  Yes

  No

  N/A

• Why?

• What is the condition of the floor? (i.e. flat, free from slip, trip or fall hazards)

  Good

  Fair

  Poor

  N/A

• How would you rate the 5S condition of the work area?

  Select Level 1 - Poor Condition Level 2 - Some organisation. Just starting Level 3 - Work in progress. Some improvements made. Level 4 - Good 5S condition Level 5 - Excellent 5S condition and best in class.

  • Level 1 - Poor Condition
  • Level 2 - Some organisation. Just starting
  • Level 3 - Work in progress. Some improvements made.
  • Level 4 - Good 5S condition
  • Level 5 - Excellent 5S condition and best in class.

• Is waste generated from the cell suitable segregated and stored in appropriate containers?

  Yes

  No

  N/A

• Give example

  Media

• Are there any examples of energy being wasted? (e.g. air leaks, oil leaks, power on when not needed etc)

  Yes

  No

  N/A

• List at least one opportunity for improvement

• Is the employee at risk of interaction/collision with vehicles / Fork lift trucks?

  Safe

  At Risk

  N/A

• Explain the issues

• Is access / egress to and from the cell clearly marked and safe?

  Safe

  At Risk

  N/A

• Is health and Safety signage apparent and visible as you enter and work around the cell? (i.e. PPE requirements, hazard signage such as chemicals, noise, temperature etc)

  Good

  Fair

  Poor

  N/A

• How would you rate the quality of the air around the cell?

  Good

  Fair

  Poor

  N/A

Standards and Procedures

• Is there a documented safe system of work for equipment normal mode of operation?

  Yes

  No

  N/A

• Is there a documented safe system of work for equipment changeovers or adjustments?

  Yes

  No

  N/A

• Is a Risk Assessment available for the cell/line/equipment or activity?

  Yes

  No

  N/A

• Do we have training records for the cell/line/equipment?

  Yes

  No

  N/A

Behaviours - Talk to the employee(s)

• Has the employee ever been injured whilst at work?

  Yes

  No

  N/A

• Is the employee aware of any near misses that have occurred in or around the area?

  Yes

  No

  N/A

• Explain the issue

• Is the employee aware of any Lost time incidents that have occurred? Ask about the A4 communications

  Yes

  No

  N/A

• Is the employee aware of any health and Safety hazards or risks in their work area that they wish to bring to your attention?

  Yes

  No

  N/A

• Note the issue(s) and action accordingly