Monthly Manufacturing Risk Assessment

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

Crushing

• Do you want to audit crushing risks?

  Yes

  No

  N/A

• Can anyone be crushed due to:

• Material falling from plant?

  Safe

  At Risk

  N/A

• Lack of capacity for the plant to be slowed, stopped or immobilised?

  Safe

  At Risk

  N/A

• The plant tipping or rolling over?

  Safe

  At Risk

  N/A

• Uncontrolled or unexpected movement of the plant or its load?

  Safe

  At Risk

  N/A

• Parts of the plant collapsing?

  Safe

  At Risk

  N/A

• Coming in contact with moving parts of the plant during testing, inspection, use, maintenance, cleaning or repair?

  Safe

  At Risk

  N/A

• Being thrown off or under the plant?

  Safe

  At Risk

  N/A

• Being trapped between the plant and materials or fixed structures?

  Safe

  At Risk

  N/A

• Add any additional crushing risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the crushing risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Entanglement

• Do you want to audit entanglement risks?

  Yes

  No

  N/A

• Can anyone be entangled due to:

• Body parts, clothing, equipment or other materials being in contact with moving parts of the plant?

  Safe

  At Risk

  N/A

• Loose ropes, cords or cables?

  Safe

  At Risk

  N/A

• Add any additional entanglement risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the entanglement risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Cutting, Stabbing and Puncturing

• Do you want to audit cutting, stabbing or puncturing risks?

  Yes

  No

  N/A

• Can anyone be cut, stabbed or punctured due to:

• Coming in contact with sharp or flying objects?

  Safe

  At Risk

  N/A

• Coming in contact with moving parts of the plant during testing, inspection, operation, maintenance, cleaning or repair of the plant?

  Safe

  At Risk

  N/A

• Parts of plant disintegrating?

  Safe

  At Risk

  N/A

• The mobility of the plant?

  Safe

  At Risk

  N/A

• Uncontrolled or unexpected movement of the plant?

  Safe

  At Risk

  N/A

• Add any additional cutting, stabbing or puncturing risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the cutting, stabbing or pucturing risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Shearing, Burning or Friction

• Do you want to audit shearing, burning or friction risks?

  Yes

  No

  N/A

• Can anyone’s body parts be:

• Burnt, gain abrasions, etc?

  Safe

  At Risk

  N/A

• Sheared in operation of plant?

  Safe

  At Risk

  N/A

• Add any additional shearing, burning or friction risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the shearing, burning or friction risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Striking

• Do you want to audit striking risks?

  Yes

  No

  N/A

• Can anyone be struck by moving objects due to:

• Uncontrolled or unexpected movement of the plant or material handled by the plant?

  Safe

  At Risk

  N/A

• Plant, parts of the plant or work pieces disintegrating?

  Safe

  At Risk

  N/A

• Work pieces being ejected?

  Safe

  At Risk

  N/A

• Mobility of the plant?

  Safe

  At Risk

  N/A

• Add any additional striking risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the striking risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

High Pressure Fluid /Gases

• Do you want to audit high pressure fluid or gas risks?

  Yes

  No

  N/A

• Can anyone come into contact with:

• Fluids/Gases under high pressure in normal use?

  Safe

  At Risk

  N/A

• In the instance of plant failure?

  Safe

  At Risk

  N/A

• Add any additional high pressure fluid/gases risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the high pressure fluid/gases risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Electrical

• Do you want to audit electrical risks?

  Yes

  No

  N/A

• Can anyone be injured by electrical shock due to:

• The plant contacting live electrical conductors?

  Safe

  At Risk

  N/A

• Electrical Leads on the ground

  Safe

  At Risk

  N/A

• Plant working close to electrical conductors?

  Safe

  At Risk

  N/A

• Overload of electrical circuits?

  Yes

  No

  N/A

• Damaged or poorly maintenance electrical components &/or cables?

  Safe

  At Risk

  N/A

• Water near electrical equipment?

  Safe

  At Risk

  N/A

• Lack of isolation procedures?

  Safe

  At Risk

  N/A

• Add any additional electrical risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the electrical risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Gases or Vapours

• Do you want to gas or vapour risks?

  Yes

  No

  N/A

• Can anyone’s health be affected by exposure to:

• Gases, vapours, liquids, dusts or other hazardous substances by the operation of the plant?

  Safe

  At Risk

  N/A

• Add any additional gas/vapour risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the gas/vapour risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Slips, Trips or Falls

• Do you want to audit slip, trip or fall risks?

  Yes

  No

  N/A

• Can anyone using the plant, or in the vicinity of the plant, slip, trip or fall due to:

• Uneven or slippery work surfaces?

  Safe

  At Risk

  N/A

• Poor housekeeping, such as shavings in the vicinity of the plant, spillage not cleaned up?

  Safe

  At Risk

  N/A

• Obstacles being placed in the vicinity of the plant?

  Safe

  At Risk

  N/A

• Add any additional slip, trip or fall risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the slip, trip or fall risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Manual Handling

• Do you want to audit manual handling risks?

  Yes

  No

  N/A

• Does use of the plant or equipment involve:

• Repetitive or sustained postures?

  Safe

  At Risk

  N/A

• High force actions?

  Safe

  At Risk

  N/A

• Jerking actions?

  Safe

  At Risk

  N/A

• Employees working with their hands above their shoulder?

  Safe

  At Risk

  N/A

• Has there been a report of musculoskeletal disorder associated with the task?

  Safe

  At Risk

  N/A

• Add any additional manual handling risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the manual handling risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Suffocation

• Do you want to audit suffocation risks?

  Yes

  No

  N/A

• Can anyone be suffocated due to:

• Lack of oxygen?

  Safe

  At Risk

  N/A

• Atmospheric contamination?

  Safe

  At Risk

  N/A

• Add any additional suffocation risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the suffocation risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Temperature

• Do you want to audit temperature risks?

  Yes

  No

  N/A

• Can anyone’s health be affected by extreme temperatures by:

• Coming into contact with objects at high temperature?

  Safe

  At Risk

  N/A

• Coming into contact with objects at Low temperature?

  Safe

  At Risk

  N/A

• Add any additional temperature risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the temperature risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Light

• Do you want to audit light risks?

  Yes

  No

  N/A

• Is the light in this area appropriate to:

• Conduct work safely?

  Safe

  At Risk

  N/A

• Ensure hazards are visible?

  Safe

  At Risk

  N/A

• Exit the area safely in an emergency situation?

  Safe

  At Risk

  N/A

• Add any additional light risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the light risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Noise

• Do you want to audit noise risks?

  Yes

  No

  N/A

• Is the noise acceptable in this area:

• To conduct work safely?

  Safe

  At Risk

  N/A

• To hear necessary instruction and warnings?

  Safe

  At Risk

  N/A

• To hear evacuation warnings?

  Safe

  At Risk

  N/A

• Add any additional noise risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

• Do any of the noise risks need mitigation?

  Yes

  No

  N/A

• Add mitigation strategies:

Mitigation Strategy

• How will these risks be mitigated?

  Select Elimination Substitution Engineering Controls Isolation Administrative Controls PPE

  • Elimination
  • Substitution
  • Engineering Controls
  • Isolation
  • Administrative Controls
  • PPE

• Please describe the mitigation strategy

Other Hazards

• Could the plant create hazardous conditions other than above mentioned categories?

  Yes

  No

  N/A

• Add any additional risks:

Risk

• Is this risk urgent?

  Urgent

  Non-Urgent

• Describe the risk

Auditor Sign-off

• Auditor to sign here

  Sign

• Date completed

  Date

• Add additional auditor:

Auditor

• Auditor to sign here

  Sign

• Date completed

  Date