Risk Assessment Checklist - Manufacturing

• Audit Title

• Document No.

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

(1). Crushing - 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

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(2). Entanglement

• Can 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

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(3). Cutting, Stabbing and Puncturing

• 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

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(4). Shearing / Burning / Friction

• 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

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(5). Striking

• 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

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(6). High Pressure Fluid /Gases

• 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

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(7). Electrical

• 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

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(8). Gases or Vapors

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

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

  Yes

  No

  N/A

• Other factors?

• Other factors?

• Add drawing

  Drawing

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(9). Slips, Trips or Falls

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

• Uneven or slippery work surfaces?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Obstacles being placed in the vicinity of the plant?

  Yes

  No

  N/A

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(10). Manual Handling

• Does use of the plant or equipment involve repetitive or sustained postures?

  Yes

  No

  N/A

• Does use of the plant or equipment involve high force actions?

  Yes

  No

  N/A

• Does use of the plant or equipment involve an jerking actions?

  Yes

  No

  N/A

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

  Yes

  No

  N/A

• Does this task require employees to be working with their hands above their shoulder?

  Yes

  No

  N/A

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(11). Suffocation

• Can anyone be suffocated due to:

• lack of oxygen

  Yes

  No

  N/A

• Atmospheric contamination?

  Yes

  No

  N/A

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(12). Temperature

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

• Coming into contact with objects at high temperature?

  Yes

  No

  N/A

• Coming into contact with objects at Low temperature?

  Yes

  No

  N/A

• Other factors?

• Other factors?

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(14). Light

• Is lighting acceptable in this area?

• Yes

  No

  N/A

• Yes

  No

  N/A

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

Noise

• Is noise acceptable in this area?

• Yes

  No

  N/A

• Yes

  No

  N/A

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

(13). Other Hazards

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

• Explosions?

  Yes

  No

  N/A

• 1. Elimination. 2. Substitution. 3. Engineering Controls. 4. Isolation. 5. Administrative Controls. 6. PPE

• Most probable result of the potential accident. <br> <br><br><br><br><br>

  Safe

  At Risk

  N/A

• CLASSIFICATION1. FACTOR

1. CONSEQUENCE

Most probable result of the potential accident.

• a. Catastrophe; numerous fatalities; major disruption of activities 100

• b. Disaster; multiple fatalities; 50

• c. Very serious; Fatality; 25

• d. Serious; serious injury (amputation, permanent disability) 15

• e. Important; disabling injury; 5

• f. Noticeable; minor cuts, bruises, bumps; minor damage. 1

2. EXPOSURE

The frequency of exposure to the hazard.

• a. Continuously (or many times daily) 10

• b. Frequently (approximately once daily). 6

• c. Occasionally (from once per week to once per month) 3

• d. Infrequent (from once per month to once per year). 2

• e. Rarely (it has been known to occur) 1

• f. Very rarely (not known to have occurred) 0.5

3. PROBABILITY

Likelihood that the consequence will occur once the individual is exposed to the hazard.

• a. Almost certain likely or expected result; 1 in 10 chance. 10

• b. Quite possible/not unusual; 1 in 10 to 1 in 100 chance 6

• c. Would be an unusual sequence or coincidence; 1 in 100 to 1 in 1000 chance 3

• d. Would be a remotely possible coincidence 1 in 1000 to 1 in 10,000 chance. 1

• e. Has never happened after many years of exposure, but is conceivably possible; 1 in 10 000 to 1 in 100,0000 0.5

• f. Practically impossible sequence (has never happened) 1 in 100,000 chance or lower 0.1

Risk Score: CONSEQUENCE X EXPOSURE X PROBABILITY. = RISK SCORE

RISK SCORE DEFINITION ACTION

• 500 Very high risk Immediate action required. HIGH PRIORITY.

• 300- 499 High risk Management attention needed. Hazards NOT adequately controlled.

• 150- 299 Substantial risk Management attention needed. Hazards NOT adequately controlled.

• 60- 149 Moderate risk Hazard must be examined against current standards

• 0- 59 Low risk Manage by routine procedures.

Hierarchy of Risk Controls

1. Eliminate

• - Is it possible to eliminate the risk?

2. Reduce

• - Is it possible to reduce the level of risk posed by the hazard by (priority order.

• · Substitution (using less hazardous alternatives)

• · Isolation (separating the operator from the risk)

• · Engineering controls (re-designing plant or equipment).

3. Administration

• - Is it possible to reduce the level of risk posed by the hazard by changing operating procedures, training, supervision, providing information etc

4. Personal Protection

• - Is it possible to reduce the level or risk posed by the hazard by wearing personal protective equipment and clothing?

Risk Control Action Plan Risk 1

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 2

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 3

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 4

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 5

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 6

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 7

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 8

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 9

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

Risk Control Action Plan Risk 10

• Completed by date/time

  Date

• Responsibility

  Select Health and Safety Department Maintenance Blending Production Warehouse Brewhouse Line Managers Manager Contractor,

  • Health and Safety Department
  • Maintenance
  • Blending
  • Production
  • Warehouse
  • Brewhouse
  • Line Managers
  • Manager
  • Contractor,

• Issue identified. Comment on progress/update for actions

• Select date

  Date

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