SLS/PROC/0001.1SMS This Baseline Risk Assessment · PDF fileAstral Risk Management was...
Transcript of SLS/PROC/0001.1SMS This Baseline Risk Assessment · PDF fileAstral Risk Management was...
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SLS/PROC/0001.1SMS
This Baseline Risk Assessment for Super Laboratory Services for 2010 is submitted in
fulfilment of the Mine Health and Safety Act of 1996 on the identification of risks by the
Owner of the Mine
Conducted, facilitated and compiled by Astral Risk Management Consultants (NHD/ B Tech SM, M Tech RM, Masters Degree)
In the
Division of Issue based Risk Assessments for mining and other industries
The next revision is required during January 2011
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Declaration
Astral RM hereby declares that this study submitted for Super Laboratory Services, is an original work and has not been duplicated to or from any Baseline Risk Assessment, and that all the sources consulted or quoted are indicated and acknowledged by means of a
comprehensive list of references.
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Synopsis Astral Risk Management was commissioned to facilitate the Baseline Risk Assessment for Super Laboratory Services on their facility as well as services rendered to industries. This Baseline was conducted on the requirements of mining legislation in the republic of South Africa. International best practices were not excluded and incorporated where necessary to reduce risks during the implementation of recommendations made in this study. Super Laboratory Services has successfully obtained accreditation to render these specialised services and comply with relevant legislation. With the introduction of the Mine Health and Safety Act, 1996 (Hereafter the “MH&S Act”), mines have to assess where they are in terms of risk, identifying the major risks and thereby establishing their priorities and a system for future risk control. This baseline Risk Assessment need to be comprehensive and may lead to further, separate, more in-depth risk assessment studies. The Baseline Risk Assessment should be periodically reviewed (see page 1, bottom of page) to ensure that it is still relevant and accurate. Issue Based and Continuous Risk Assessments will need to be incorporated to address the identified major risk areas continuously. The Baseline Risk Assessment for Super Laboratory Services was conducted through site risk audits, workshops with management and employees as well as document assessment. Available historical data such as accidents and incident reports, inspections and audits done, as well as plans were studied to assess the risk record of Super Laboratory Services. Risk Audits Risk Audits were carried out by means of checklists on best practices in the mining industry. The Auditors used the following checklists: Facility and offices checklist; Calibration of equipment; Planned inspection checklist. Workshop A workshop was conducted with management and employees on 12 January 2010. Document assessment All available documents were studied and any unclear issues with regard to documents or plans discussed during the workshop session. Historical data All available historical data of Super Laboratory Services was researched and analysed. Note was taken of industry and international data for the Baseline Risk Assessment. Main Findings The findings indicate that the risks can be well managed within a proper Health and Safety Management system. Risks can be controlled to ensure a safe working environment for Super Laboratory Services employees. The risk levels of risks identified were very low. Certain areas of concern will be mentioned in the study and current controls evaluated.
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Main Recommendations Issue Based Risk Assessments As circumstances and needs arise, separate risk assessment studies need to be conducted. These will normally be associated with a system for the management of change. An additional risk assessment needs to be carried out when, for example:
• New equipment and machinery are introduced. • A system of work is changed or operations alter from the current. • After a serious accident or re-occurrence of similar types of incidents/ accidents
occur. • As new knowledge comes to light and information is received which may influence
the level of risk to Super Laboratory Services employees. Continuous Risk Assessments This is the most important form of risk assessment, which should take place continually, as an integral part of day-to-day management. It may not be as sophisticated as the hazard and risk assessment tools used for Baseline and Issue Based Risk Assessments, but in terms of ensuring safety and absence of health risks in the workplace, this form of risk assessment is the most powerful and important. Examples of Continuous Risk Assessment include: • Audits. • General hazard awareness linked to a campaign. • Pre-work assessments using checklists. (Planned Task Observations, Critical Parts and Task
Analyses, etc.). • Risk Assessments using a Risk Index/ Matrix method. Health and safety Management system To comply with the Mine Health and Safety Act requirements, a proper Health and Safety Management system as per OHSASH 18001 needs to be maintained. Acknowledgements The Management and Employees of Super Laboratory Services assisted with this study. Consultants who are competent in their field of expertise by way of knowledge, qualification, and experience in mining, metallurgy and engineering were used to assist in the assessment.
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Table of contents 1. Introduction 1.1 Competency of Assessors
1.2 Background of Super Laboratory Services
1.3 Legal requirements
1.4 Research problems
1.5 Reason for study
1.6 Research methodology and research design
1.7 Limitations of research 2. Review of data 2.1 Introduction 2.2 Historical data analysis
2.3 Identified problem areas for the physical conditions, processes, equipment, materials and the environment.
2.4 Behaviour based safety Analysis 2.5 Exposition of the problem 2.6 Competency requirements 2.7 Conclusion 3. Baseline Analysis 3.1 Occupational levels 3.2 Activity levels 3.3 Task levels 4. Strategy, levels of strategy and graphic representation of Baseline 4.1 Overall strategy 4.2 Operational strategy 4.3 Graphic representation of Baseline 5. Findings and recommendations 5.1 Findings
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5.2 Recommendations 5.3 Conclusion 6. Bibliography Appendix
A. Cover letter addressed to Super laboratory Services clients
B. Plans for Baseline area
C. Checklists for next revision
D. References
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1. Introduction 1.1 Competency of Assessors Astral Risk management was established in 1995. Astral is a risk management service company for national and international industries as well as the South African government. Astral Risk management is serving companies operating in the micro as well as the macro environment.
Astral is a service vehicle, which operates mainly by contracting-in expert consultants or companies, preferably, and by first choice, HDSA consultants or BEE compliant companies. This ensures the creation of a job market, which was never tapped into. Services, solutions and delivery capacity Astral’s key strength is the flexibility and depth of services and solutions. We analyse all complex risk control requirements and provide the answers. Through the application of tailored services and solution packages we consistently demonstrate our ability to beat our competitors when it comes to successfully completing complex risk management assignments. Astral offers solutions through multiple national and international methodologies and principles and ensures speedy results and solutions for risk management issues. We provide service capacity with regard to competent Safety and Risk management personnel available for the market. Astral is a dedicated alliance to company specific risk management needs through the capacity to deliver a professional and internationally acceptable solution to risk management problems. Risk assessments
We apply internationally accredited risk assessment tools to systems, products, manufacturing processes, equipment, plant and even less tangible subjects such as logistic or information flows. The risk assessment process is used to identify the possible ways in which failure could occur, the corresponding causes of failure, the corresponding effects of failure, and the impact on customer satisfaction as well as any implication of legal liability. 1.2 Background of Super Laboratory Services.
Their values Integrity Respect Responsibility and accountability Dedication Mission statement “To provide a trustworthy cost effective and safe analytical service to all our customers (big or small), this enables them to concentrate on their core business”
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Brief historical background Super Laboratory Services (Pty.) Ltd. (S.L.S.) was started in 1996, primarily to service Nigel Gold Mine, a small gold mine based at the old Springs Daggafontein property. The laboratory was situated in Nuffield on the old Raleigh Cycles premises. The initial owners were Nigel Gold Mines (which have since become Pamodzi Gold), Waste Products Utilisation (which have sold their shares back to S.L.S.) and K. B. (Ken) Gibbons. In 1998 S.L.S. opened a branch in Barberton on the Agnes Gold Mines premises. In 2002, S.L.S. opened a branch in Klerksdorp, an Afrikander Lease Gold Mines property (which has since become Uranium One – Rietkuil operations). S.L.S. is committed to their present operations, but also has plans to expand and diversify. Scope of operation of Super Laboratory Services (a) Chemical analysis of gold-bearing mineral ores, solutions, concentrates and bullion, by employing amongst other, the following techniques: i) fire assay analysis of gold and gravimetric finish; ii) AAS analysis of gold and base metals in solution; and (b) Metallurgical test work; (c) Carbon test work; (d) Grading analysis of crushed and milled ore samples; (e) Classical wet analysis, such as cyanide and lime titrations Sample Receiving (Bulks)
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Sample Receiving (Batching on LIMS
Drying Tables & Pulverising Room
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Sample Batching & Sample fluxing (Fluxing on LIMS)
Furnaces & Muffles
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Parting & Weighing (Weighing on LIMS
1.3 Legal requirements Compliance to the following legislation or best practice/ guideline is required:
•The SIMRAC guideline •The MHSA 1996 •International Risk Principles •ILO OHSAS 18002 •National Nuclear Act •SAQA Act •Hazards Substances Act •Workmen’s Compensation Act •COID Act •Atmospheric Pollution Prevention Act •Labour Relations Act •Employee Equity Act •Skills Development Act •Lead regulations 2001 •Environment conservation Act •OHS Act •BCE Act •Harmful Businesses Practice Act •Precious metals Act of 2005
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1.4 Research problems The levels of risk identified during this study are low and no significant risk exposure has been identified. However, the information gathered shows a quite clear picture of where the major risk areas lay and what precautions are being taken to mitigate the risks. 1.5 Reason for study
Astral was commissioned by Super Laboratory Services to conduct a baseline Risk Assessment of its facility and services. The baseline area is contained within the site only, and does not include any transport to and from the Laboratory, as this responsibility lies with the clients who deliver the material to the Laboratory.
1.6 Research methodology and research design
The risk assessment process (Extracted from the tripartite working group on risk assessment (25 March 1996, based on international risk principles, ref. DNV, Switzerland)
Baseline risk assessment With the introduction of the MH&S Act, mines have to assess where they are in terms of risk, identifying the major risks and thereby establishing their priorities and a system for future risk control. This responsibility includes services rendered by outside companies. Owners of mines are obliged to request a Baseline Risk Assessment from Manufacturers or Service Providers to ensure the product or service complies with Section 21 of the Mine Health and Safety Act of 1996. This Baseline Risk Assessment is comprehensive and may well lead to further, separate, more in-depth risk assessment studies. The Baseline Risk Assessment should be periodically reviewed to ensure that it is still relevant and accurate. Issue Based and Continuous Risk Assessments will need to be incorporated to achieve the “complete picture”. 1.7 Limitations of research
Limitations of the research include past and current assessment and needs to be revised annually as risks may change.
2. Review of data The review includes historical as well as current data obtained through audits, interviews and research. 2.1 Introduction Competent Consultants were used in collecting the data. Interviews with the current personnel took place on site or during the workshop. Historical data was obtained from Super Laboratory Services such as records, plans and on-site contractor procedures (SOP’s).
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2.2 Historical data analysis The following data was scrutinized and analysed to produce a clear picture of possible future repetitive problem areas, activities which have a high likelihood to result in a downgrading incident or accident, and tasks which could result in a behavioural error.
Inspection reports Task Analysis for similar activities Critical Task Analysis Accident/ Incident statistics Risk Audits Risk Assessments
2.3 Identified problem areas for the physical conditions, processes, equipment, materials and the environment. The following graphic representations show the potential risk variations of prominent health and safety issues within distinctive areas. No Functional
area Task
Risk level
Risk Controls
1 Sample receiving
Physical offloading of samples
Low Personal injury, Loss of samples
PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
2 Bulk sample preparation
Reduce size of rock Low FB in eye, personal injury
PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
3 Reduce the mass of crushed rock
Low FB in eye, personal injury
PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
4 Physical movement of prepared samples to the drying area
Low Slip & fall, falling objects
PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
5 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
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No Functional area
Task
Risk level
Risk Controls
6 Sample preparation
Placing the dish and sample into the drying facility
Low
Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
7 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
8 Crushing
Reduce size of rock Low FB in eye, personal injury
PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
9 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
10 Pulverising
Place new discs in Pulverisor if necessary
Low Hand injuries PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
11 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
12 Batching
Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
13 Fluxing
Physical inspection of crucibles
Low Hand injuries PPE, SOP Supervision Training Planned inspections
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No Functional area
Task
Risk level
Risk Controls
PTO’s Continuous risk assessments
14 Addition of flux mixture to crucibles
Low Dust and lead Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
15 Mixing of material in crucible
Low Dust and lead Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
16 Physical placement of tray at furnaces
Low Slipping and falling
Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
17 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
18 Furnaces
Preparation of furnace before loading
Low Respiratory problems and contamination
Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
19 Placing of crucibles in furnace
Low Contamination, Burning
PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
20 Inspection of fusion process
Low Burning PPE, SOP Supervision Training Planned inspections
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No Functional area
Task
Risk level
Risk Controls
PTO’s Continuous risk assessments
21 Preparation of receiving moulds
Low Contamination, Burning, Falling objects
PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
22 Determine fusion is complete
Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
23 Pouring of the fused material
Low Contamination, Burning, Falling objects
PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
24 Transfer trolley to Cupellation
Low Contamination, Burning, Falling objects
PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
25 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
26 Muffle
Deslagging of lead button from mould
Low Hand injuries, FB, Burning
PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
27 Hammering of lead button
Low Hand injuries, FB, Burning
PPE, Gloves - heat resistant, SOP Supervision Training
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No Functional area
Task
Risk level
Risk Controls
Planned inspections PTO’s Continuous risk assessments
28 Placement of lead button onto Cupel
Low Heat/ Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
29 Inspection of Cupellation process
Low Heat/ Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
30 Removal of Cupel tray after determining processes complete
Low Heat/ Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
31 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
32 Parting
Addition of parting acid
Low Acid burn PPE, Gloves & overalls - acid resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
33 Drying of sample Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
34 Annealing of sample Low Burning PPE, Gloves - heat resistant, SOP Supervision
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No Functional area
Task
Risk level
Risk Controls
Training Planned inspections PTO’s Continuous risk assessments
35 Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
36 Weighing
Cleaning to prevent contamination
Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
No Processes,
Equipment, material Risk level
Risk Controls
1 Furnace Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
2 Muffle Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
3 Hotplates & water baths
Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
4 Drying tables Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
5 Crusher Low Personal injuries particularly hand injuries and FB in eye
PPE - Safety Glasses, Ear plugs, safety shoes, dust masks. Dust extraction system. SOP Supervision Training Planned inspections PTO’s
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No Processes, Equipment, material
Risk level
Risk Controls
Continuous risk assessments 6 Pulveriser Low Dust
inhalation & Personal injury
PPE – Dust masks, gloves when changing discs, Dust extraction system. SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
7 Swing mill Low Dust inhalation & Personal injury
Dust extraction system. SOP Supervision Training Planned inspections PTO’s Continuous risk assessments
No General
Risk Detail
1 Appointments MHS Act
Low Not required
2 Planned Inspections & Follow-up
Low Monthly
3 Planned Task Observations
Low Daily
4 Procedures and training thereof
Low Monthly
5 Safety meetings recorded
Low Minutes of meetings
6 Safety system OHSASH 18001
Low Implementing required elements for business
2.4 Behaviour based safety Analysis No Behaviour related
Risk Detail
1 Emergency Preparedness awareness
Low Emergency preparedness and response to incidents (proactive action). One minor accident recorded in existence of business
2 Corrective action on Planned Inspections
Low Follow up system on work done
3 Routine work "Auto Pilot"
Medium Supervision and motivation
4 Hazard awareness and compliance to planned objectives
Medium On the job training, Planned Task Observations
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2.5 Exposition of the problem
Super laboratory Services is responsible for the Laboratory and the activities on their premises only. Small amounts of sample material are handled, resulting in a low risk working environment. One minor cut of the finger accident is on record.
2.6 Competency requirements
2.6.1 Policy 2.6.1.1 Super Laboratory Services shall use personnel who are employed by, or under contract to the laboratory. 2.6.1.2 Laboratory management shall ensure the competence of all who operate specific equipment, perform tests, evaluate results and sign test reports. 2.6.1.3 Personnel performing specific tasks shall be qualified (considered to be competent) on the grounds of appropriate education, training, experience and/or demonstrated skills, as required (refer to the appendix to this section titled: “Requirements for competency”). 2.6.1.4 Where contracted and additional technical and key support personnel are used, the laboratory shall ensure that such personnel are supervised and competent and that they work in accordance with the management system related to quality of the laboratory. 2.6.2 Procedure Goals with respect to the education, training and skills of laboratory personnel: 2.6.2.1 Goals with respect to the education, training and skills of laboratory personnel shall be formulated and documented at biannual management reviews (refer to the appendix to this section titled: “Training goals for personnel”, for an example of such a record). 2.6.2.2 The training programme shall be relevant to the present and anticipated tasks of the laboratory. 2.6.2.3 The laboratory shall be responsible for fulfilling specified personnel certification requirements in instances where regulatory authorities, standards for the specific technical field or customers require personnel performing certain tasks to hold personnel certification. 2.6.3 Identification of training needs 2.6.3.1 Training, retraining and courses or sessions to develop and improve skills of personnel can be initiated at any time by the Laboratory Manager or Quality Manager in response to amongst other: a) decisions reached at management reviews; b) customer requests; c) corrective actions; and d) other strategic and operational issues. 2.6.4 Training and competency testing of personnel 2.6.4.1 Trainees shall be afforded access to relevant test methods, procedures and subject matter.
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2.6.4.2 The Laboratory Supervisor or qualified deputy shall explain the contents of applicable documentation to the trainee and impart as much related information as is necessary to ensure that the trainee has a thorough understanding of the documentation. 2.6.4.3 The trainer shall then demonstrate the test method or task and all associated procedures to the trainee, ensuring that the trainee is made aware of how information contained in the documentation is applied in practice and in accordance with the management system of the laboratory. 2.6.4.5 The trainee shall be allowed to familiarise him/her with both the theoretical and practical aspects of the test method or task and any ancillary procedures, while working under the supervision of a qualified person. 2.6.4.6 The period of familiarisation, further training and skills development shall be in accordance with the appendix to this section titled: “Requirements for competency”. 2.6.4.7 Upon completion of the familiarisation period, the trainee shall be required to undergo an examination on the theoretical and/or practical aspects of the test method or task. The examination shall be conducted by the Quality Manager in accordance with criteria set for each test method/task in the appendix to this section titled: “Requirements for competency”. 2.6.4.8 Assessment of the practical performance of the trainee shall be based on results obtained in a formal practical test or during method validation and/or proficiency tests. 2.6.4.9 The Quality Manager shall retain all marked answer papers in a training file, kept in his/her office. 2.6.4.10 The Quality Manager shall inform the trainee of the results of the examination and update the competency records (refer to the appendix to this section titled: “Record of competency”, for an example of such a record). 2.6.4.11 Unsuccessful candidates shall be treated in accordance with decisions reached between the Laboratory Manager and the Quality Manager. 2.6.4.12 Successful candidates shall be considered competent and authorised to conduct the test method or task. 2.6.5 Authorisation of personnel to perform certain tasks 2.6.5.1 Laboratory management shall authorise specific personnel to: a) perform particular types of sampling; b) perform particular types of testing; c) issue test reports (subject to SANAS authorisation); d) to give opinions and interpretations; e) to operate particular types of equipment. 2.6.5.2 Personnel responsible for the opinions and interpretation included in test reports shall, in addition to the appropriate qualifications, training, experience and satisfactory knowledge of the testing carried out, also have:
a) relevant knowledge of the technology used for the manufacturing of the items, materials, products, etc. tested, or the way they are used or intended to be used, and of the defects or degradations which may occur during or in service;
b) knowledge of the general requirements expressed in the legislation and standards; and;
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c) an understanding of the significance of deviations found with regard to the normal use of the items, materials, products, etc. concerned.
2.6.6 Maintenance of records of qualifications and training 2.6.6.1 The laboratory shall maintain records of the relevant educational and professional qualifications and experience of all technical personnel, including contracted personnel, in a training file, kept in the Quality Manager’s office. 2.6.6.2 The laboratory shall maintain records of the relevant training, authorisation(s), competence and skills of all technical personnel, including contracted personnel (refer to the appendix to this section titled: “Record of competency”). 2.6.6.3 Information regarding qualifications and training shall be readily available, and shall include the date on which authorisation and/or competence is confirmed. 2.6.6.4 Personnel shall be responsible for providing the Quality Manager with details of educational and professional qualifications and experience attained. 2.6.6.5 The Quality Manager shall be responsible for the maintenance of records of qualifications and training. 2.6.7 Effectiveness of training actions taken The effectiveness of the training actions taken shall be evaluated at biannual management reviews, taking into account amongst other:
a) marks obtained by trainees in theoretical exams and/or practical tests; and;
b) any increase in individual performance that can be attributed to training efforts.
2.6.8 Job descriptions The Laboratory Manager shall maintain current job descriptions for managerial, technical and key support personnel involved in testing, in which, as a minimum, the following shall be defined (refer to the section titled: “Organisation”): a) the responsibilities with respect to performing tests; b) the responsibilities with respect to the planning of tests and evaluation of
results; c) the responsibilities for reporting opinions and interpretations; d) the responsibilities with respect to method modification and development and validation of new methods; e) expertise and experience required; f) qualifications and training programmes; g) managerial duties.
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2.6.9 Related records
Identification Requirements for
competency to perform certain
tasks
Training goals for personnel Training record
Responsibility for collection, indexing and filing of records Quality Manager Quality Manager Quality Manager
Where kept Quality Manager’s office
Quality Manager’s office
Quality Manager’s office
Responsibility for maintenance of records Quality Manager Quality Manager Quality Manager
Access All staff All staff All staff
Responsibility for disposal of records Quality Manager Quality Manager Quality Manager
Retention time of records Indefinitely Indefinitely Indefinitely
2.7 Conclusion
Risk levels for Super Laboratory Services were rated low on the Risk matrix (See appendix page 43). Business continuity will not be affected as processes also fall within the low risk level.
3. Baseline Analysis The following occupation analysis demonstrates the risk levels as per the depicted Baseline area. Occupational levels At risk performance/ tasks No Occupation
Risk Detail
1 Director Low Monitor performance
2 Sample Receiver Low Detect substandard performance, correct & and monitor
3 Crusher Operator Low Prevent substandard performance at source
4 Section Leader Low Detect substandard performance, correct & and monitor
5 Lab. Operator
Low Detect substandard performance, correct & and monitor
6 Batcher Low Detect substandard performance, correct & and monitor
7 Fluxer Low Detect substandard performance, correct & and monitor
8 Furnace Operator Low Detect substandard performance, correct &
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No Occupation
Risk Detail
and monitor
9 Lab Analyst Low Low risk occupation
10 Data Capturer Low Low risk occupation
Activity levels No Grouped activities
Risk Detail
1 Offloading Low Detect substandard performance, correct & and monitor
2 Inspecting Low Monitor performance
3 Correlation Low Monitor performance
4 Crushing Low Detect substandard performance, correct & and monitor
5 Splitting/ Riffling Low Detect substandard performance, correct & and monitor
6 Transfer to next section Low Monitor performance
7 Transferring sample from received packet into sample dish
Low Monitor performance
8 Drying samples Low Detect substandard performance, correct & and monitor
9 Recording sample ID onto sample packet
Low Monitor performance
10 Pulverising Low Detect substandard performance, correct & and monitor
11 Sorting of samples Low Monitor performance
12 Preparation of batch Low Monitor performance
13 Transferring of the batch to fluxing
Low Monitor performance
14 Preparation of furnace tray Low Detect substandard performance, correct & and monitor
15 Weighing of samples Low Monitor performance
16 Loading/ unloading - Furnace Low Detect substandard performance, correct & and monitor
17 Muffling Low Monitor performance
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No Grouped activities
Risk Detail
18 Parting Low Monitor performance
19 Weighing Low Monitor performance
20 Reporting - Liaison with
customer Low Monitor performance
3.3 Task levels No Grouped tasks
Risk Detail
1 Physical offloading of samples
Low Detect substandard performance, correct & and monitor
2 Inspecting sample bags Low Monitor performance
3 Counting of samples Low Monitor performance
4 Checking paper work against the physical samples in presence of Customer
Low Monitor performance
5 Creating a worksheet on the LIMS system
Low Monitor performance
6 Record and rectify any discrepancies
Low Monitor performance
7 Reduce size of rock Low Detect substandard performance, correct & and monitor
8 Collecting of crushed rock Low Detect substandard performance, correct & and monitor
9 Reduce the mass of crushed rock
Low Detect substandard performance, correct & and monitor
10 Collecting of crushed rock
Low Detect substandard performance, correct & and monitor
11 Logging of sample ID's Low Monitor performance
12 Physical movement of prepared samples to the drying area
Low Detect substandard performance, correct & and monitor
13 Cleaning to prevent contamination
Low Detect substandard performance, correct & and monitor
14 Emptying of sample packet into sample dish
Low Detect substandard performance, correct & and monitor
15 Ensure ticket remains with sample
Low Monitor performance
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No Grouped tasks
Risk Detail
16 Placing the dish and sample into the drying facility
Low Detect substandard performance, correct & and monitor
17 Ensure the sample is fully dried
Low Detect substandard performance, correct & and monitor
18 Writing sample ID onto brown paper bag
Low Monitor performance
19 Collecting of crushed rock
Low Detect substandard performance, correct & and monitor
20 Placing sample into Pulveriser
Low Detect substandard performance, correct & and monitor
21 Collects pulverised material
Low Detect substandard performance, correct & and monitor
22 Check whether pulverised material is of the correct fineness
Low Detect substandard performance, correct & and monitor
23 Place new discs in Pulveriser if necessary
Low Detect substandard performance, correct & and monitor
24 Numerical sorting of packets Low Monitor performance
25 Physical inspection of sample ID's
Low Detect substandard performance, correct & and monitor
26 Placing the sorted packets into trays according to the worksheets created at sample receiving
Low Detect substandard performance, correct & and monitor
27 Physical placement of tray at fluxing
Low Detect substandard performance, correct & and monitor
28 Physical inspection of crucibles
Low Detect substandard performance, correct & and monitor
29 Correlation of tray against worksheet
Low Monitor performance
30 Addition of flux mixture to crucibles
Low Detect substandard performance, correct & and monitor
31 Transfer of sample aliquot to crucibles as per worksheet
Low Detect substandard performance, correct & and monitor
32 Capturing of sample on LIMS Low Monitor performance
33 Mixing of material in crucible
Low Detect substandard performance, correct & and monitor
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No Grouped tasks
Risk Detail
34 Addition of silver
Low Detect substandard performance, correct & and monitor
35 Coppering of tray for tray ID purposes
Low Detect substandard performance, correct & and monitor
36 Physical placement of tray at furnaces
Low Detect substandard performance, correct & and monitor
37 Completing worksheet Low Monitor performance
38 Determine fusion is complete
Low Detect substandard performance, correct & and monitor
39 Pouring of the fused material
Low Detect substandard performance, correct & and monitor
40 Recording of process Low Monitor performance
41 Transfer trolley to Cupellation
Low Detect substandard performance, correct & and monitor
42 Deslagging of lead button from mould
Low Detect substandard performance, correct & and monitor
43 Preparation of Cupels as per worksheet from furnace room
Low Detect substandard performance, correct & and monitor
44 Hammering of lead button
Low Detect substandard performance, correct & and monitor
45 Placement of lead button onto Cupel
Low Detect substandard performance, correct & and monitor
46 Inspection of Cupellation process
Low Detect substandard performance, correct & and monitor
47 Removal of Cupel tray after determining processes complete
Low Detect substandard performance, correct & and monitor
48 Correlation of worksheet against completed Cupel tray
Low Monitor performance
49 Transfer Cupel tray to parting area
Low Detect substandard performance, correct & and monitor
50 Correlation of worksheet against Cupel tray
Low Monitor performance
51 Preparation of parting tray
Low Detect substandard performance, correct & and monitor
52 Hammering of Prill Low Detect substandard performance, correct &
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No Grouped tasks
Risk Detail
and monitor
53 Transfer Prill to parting cups
Low Detect substandard performance, correct & and monitor
54 Addition of parting acid
Low Detect substandard performance, correct & and monitor
55 Addition of strong acid
Low Detect substandard performance, correct & and monitor
56 Washing of sample
Low Detect substandard performance, correct & and monitor
57 Drying of sample
Low Detect substandard performance, correct & and monitor
58 Annealing of sample
Low Detect substandard performance, correct & and monitor
59 Completion of worksheet
Low Detect substandard performance, correct & and monitor
60 Transfer of parting tray to weighing area
Low Detect substandard performance, correct & and monitor
61 Calibration of microbalance Low Monitor performance
62 Inspection of parting tray against worksheet
Low Monitor performance
63 Obtain the relevant microbalance worksheet from LIMS
Low Monitor performance
64 Transfer sample from cup to microbalance
Low Detect substandard performance, correct & and monitor
65 Record mass Low Monitor performance
66 Print microbalance worksheet
Low Monitor performance
67 Correlate microbalance worksheet to worksheet
Low Monitor performance
68 Attach microbalance worksheet to worksheet
Low Monitor performance
69 Transfer completed document to reporting office
Low Monitor performance
70 Preparation of report sheet Low Monitor performance 71 Correlation of microbalance
sheet, worksheet and request sheet
Low Monitor performance
31
No Grouped tasks
Risk Detail
72 Protection of information Low Monitor performance 73 Filing of documents Low Monitor performance 74 Ensure customer receives
requested information timeously
Low Monitor performance
75 Ensure customer is satisfied with results
Low Monitor performance
76 Communication with customer
Low Monitor performance
77 Providing consultation to customer
Low Monitor performance
4. Strategy, levels of strategy and graphic representation of Baseline 4.1 Overall strategy To provide a trustworthy, safe and cost effective analytical service to all our customers (big or small) this enables them to concentrate on their core business. (See appendix – page 61) 4.2 Operational strategy 4.2.1 Safe operation of the following: (a) Chemical analysis of gold-bearing mineral ores, solutions, concentrates and bullion, by
employing amongst other, the following techniques: i) fire assay analysis of gold and gravimetric finish; ii) AAS analysis of gold and base metals in solution; and (b) Metallurgical test work; (c) Carbon test work; (d) Grading analysis of crushed and milled ore samples; (e) Classical wet analysis, such as cyanide and lime titrations 4.2.2 Proactive detection of substandard performances or conditions, correct immediately & and monitor. 4.2.3 Continuous health and safety training of employees (see 2.6.4) 4.3 Graphic representation of Baseline The risk values have been converted from the checklist criteria (see appendix page 41) to a more effective value display in the graphs. The risk profiles reflect the control effectiveness of current controls (residual risk) versus risk without controls (inherent risk). Assessment areas were combined to show a weighted average per item.
32
0
50
100
150
200
250
Sam
ple
rece
ivin
g
Bulk
sam
ple
prep
.
Crus
hing
Batc
hing
Pulv
erisi
ng
Sam
ple
rece
ivin
g
Furn
aces
Flux
ing
Muf
fle
Part
ing
Wei
ghin
g
Repo
rtin
g
Functional Risk Profile
Inherent rating
Residual rating
1 to 100 = Low risk 300 to 1000 = Medium risk 900 to 10000 = High risk Inherent = risk levels without controls
0
50
100
150
200
250
Lab.
Ope
rato
r
Sect
ion
Lead
er
Crus
her O
pera
tor
Crus
her O
pera
tor
Batc
her
Sam
ple
Rece
iver
Furn
ace
Ope
rato
r
Flux
er
Lab
Anal
yst
Data
Cap
ture
r
Dire
ctor
Occupational Risk Profile
Inherent
Residual
1 to 100 = Low risk 300 to 1000 = Medium risk 900 to 10000 = High riskInherent = risk levels without controls Residual = risk levels with controls
33
Total Task Risk Profile (including health and safety related tasks) 1-100= Low risk 300- 1000= Medium risk 900-10000= High risk Tasks Inherent Residual Emptying of sample packet into sample dish 90 90 Ensure ticket remains with sample 300 90 Checking paper work against the physical samples in presence of Customer 300 30 Cleaning to prevent contamination 100 30 Collecting of crushed rock 300 30 Collects pulverised material 300 30 Logging of sample ID's 100 30 Numerical sorting of packets 100 30 Physical movement of prepared samples to the drying area 100 30 Pouring of the fused material 300 30 Record and rectify any discrepancies 300 30 Reduce size of rock 300 30 Transfer of parting tray to weighing area 300 30 Creating a worksheet on the LIMS system 100 10 Inspecting sample bags 100 10 Physical placement of tray at fluxing 90 10 Placing sample into Pulveriser 90 10 Placing the dish and sample into the drying facility 30 10 Placing the sorted packets into trays according to the worksheets created at sample receiving 90 10 Record and rectify any discrepancies 100 10 Check whether pulverised material is of the correct fineness 100 9 Coppering of tray for tray ID purposes 30 9 Correlation of worksheet against completed Cupel tray 100 9 Determine fusion is complete 100 9 Ensure the sample is fully dried 30 9 Inspection of fusion process 100 9 Physical inspection of sample ID's 30 9 Physical inspection of tray against worksheet 100 9 Place new discs in Pulveriser if necessary 100 9 Placement of lead button onto Cupel 300 9 Placing of crucibles in furnace 100 9 Preparation of furnace before loading 100 9 Record mass 100 9 Recording of process 100 9 Reduce the mass of crushed rock 100 9 Removal of Cupel tray after determining processes complete 100 9
34
Tasks Inherent Residual Transfer Prill to parting cups 100 9 Transfer sample from cup to microbalance 300 9 Addition of parting acid 30 3 Addition of silver 30 3 Addition of strong acid 30 3 Attach microbalance worksheet to worksheet 30 3 Capturing of sample on LIMS 30 3 Completing worksheet 30 3 Correlate microbalance worksheet to worksheet 100 3 Correlation of microbalance sheet, worksheet and request sheet 90 3 Counting of samples 300 3 Drying of sample 30 3 Ensure customer receives requested information timeously 30 3 Hammering of lead button 30 3 Hammering of Prill 30 3 Inspection of Cupellation process 30 3 Obtain the relevant microbalance worksheet from LIMS 100 3 Physical placement of tray at furnaces 30 3 Preparation of Cupels as per worksheet from furnace room 30 3 Preparation of parting tray 30 3 Preparation of report sheet 30 3 Print microbalance worksheet 100 3 Protection of information 100 3 Transfer completed document to reporting office 30 3 Transfer Cupel tray to parting area 100 3 Transfer trolley to Cupellation 30 3 Washing of sample 100 3 Writing sample ID onto brown paper bag 30 3 Annealing of sample 9 1 Communication with customer 9 1 Deslagging of lead button from mould 30 1 Ensure customer is satisfied with results 9 1 Filing of documents 9 1 Inspection of parting tray against worksheet 30 1 Mixing of material in crucible 9 1 Physical offloading of samples 9 1 Preparation of receiving moulds 9 1 Providing consultation to customer 9 1 Recording of fusion process 9 1
35
Top 10 tasks Risk Profile
0
50
100
150
200
250
300
350
Empt
ying
of s
ampl
e pa
cket
into
sam
ple
dish
Ensu
re ti
cket
rem
ains
with
sam
ple
Chec
king
pap
er w
ork
agai
nst
the
phys
ical
sam
ples
in
pres
ence
of C
usto
mer
Clea
ning
to p
reve
nt co
ntam
inat
ion
Colle
ctin
g of c
rush
ed ro
ck
Colle
cts p
ulve
rised
mat
eria
l
Logg
ing
of sa
mpl
e ID
's
Num
eric
al so
rtin
g of
pac
kets
Phys
ical
mov
emen
t of p
repa
red
sam
ples
to th
e dr
ying
ar
ea
Pour
ing o
f the
fuse
d m
ater
ial
Top 10 Task Risk Profile
Inherent
Residual
1 to 100 = Low risk 300 to 1000 = Medium risk 900 to 10000 = High risk Inherent = risk levels without controls Residual = risk levels with controls
36
5. Findings and recommendations 5.1. Findings
5.1.1. The risk levels at the laboratory are low and proper controls are in place 5.1.2. Legal requirements for this operation is monitored and inspected by the Labour Department Inspectorate who visits the site frequently. 5.2. Recommendations Continue with close supervision and on the job training. 5.3. Conclusions With the required resources available the strategy plan can be implemented successfully.
6. Bibliography Appendices to follow
37
A. Cover letter addressed to Super laboratory Management
Super Laboratory Services The Director
Astral Risk Management P.O.Box 6599
Greenhills
Baseline Risk Assessment Super laboratory Services
Sir,
As requested, herewith the Baseline Risk Assessment for Super Laboratory Services.
The Baseline includes business as well as operational health and safety issues.
The Baseline will reflect the major risks for the Baseline area through graphical presentations of the levels of risks for functional areas, activities, occupations and tasks.
In addition, external historical data has also been analysed to identify any other possible failures. This includes investigation into previous significant incidents or accidents, current historical data of the working environment and failure of critical structures or machinery.
Implementation of the current strategy will ensure not only legal compliance but also ensures a more effective and proactive approach to maintain a safe working environment.
The utilisation of expert Consultants ensured that the data obtained has been correctly analysed and presented in an understandable manner.
Checklists have also been included for future use. DS Germishuizen CEO Astral Risk Management
38
B. Plans for Baseline area
The plans for Super Laboratory Services.
39
40
C. Criteria and Audit checklists C.1 Risk Criteria C.1.1 Impact criteria:
Criteria No Level of impact Risk value
Health & Safety Legal/ Governmental/ Regulatory Operational Community Environmental Security Procurement
1 Significant irreversible health & Safety effects to >50 persons; Significant prosecution and fines. Very serious litigation, including class actions.
100
2 Single fatality and/or severe irreversible disability (>30%) to one or more persons; Major breach of regulation. Major litigation.
30
3 Moderate irreversible disability or impairment (<30%) to one or more persons; Serious breach of regulation with investigation or report to authority with prosecution and/ or moderate fine possible
10
4 Objective but reversible disability requiring hospitalisation; Minor legal issues, non-compliances and breaches of regulation.
3
5 No medical treatment required – Incidental/ Near miss; Low-level legal issue.
1
C 1.2 Likelihood of occurrence
Likelihood
Category
Category Description Risk value
Almost certain The risk is almost certain to occur in the current circumstances
100
Likely More than an even chance of occurring 30
Possible Could occur quite often 10
Unlikely Small likelihood but could happen 3
Rare Not expected to happen – Event would be a surprise 1
41
C.1.3 Inherent risk (Risk without controls)
The risk rating equals the impact multiplied with the Likelihood.
Category Category Description Risk rating from
checklists
Extreme This risk should be terminated / insured / controlled 10 000
High This risk should be insured / controlled 6000
Moderate This risk will typically be controlled (treated) 3000
Low Management will make an informed decision as to whether this risk must be controlled or absorbed by the business unit. The decision will be based on a “cost vs. benefit” approach
100
Insignificant Impact and probability is insignificant. This risk may be tolerated, and cost of losses will be absorbed by the business unit
1
C.1.4 Control effectiveness on residual risk (Risk with current controls)
Category Level Category Description Risk rating from
checklists
Extreme Immediate action
required
Management should take immediate action to reduce residual risk exposure to an acceptable level.
10 000
Very High Action required
Management should implement more controls or increase the effectiveness of current controls to reduce the residual risk to a more acceptable level.
6000
High Monitor Management should constantly monitor the risk exposure and related control effectiveness.
3000
Moderate Acceptable The residual risk exposure is acceptable to the mine.
100
Low Reduce control
Management may consider reducing the cost of control.
1
42
Risk scoring chart or “Vulnerability Risk Assessment” – This scoring gives the following risk ranking assessed for each risk on consequence versus probability/ Likelihood: High risk – Score of 900-10000 Medium risk – Score of 300-1000 Low risk – Score of 1-100
Con
sequ
ence
/ Im
pact
C
onse
quen
ce/ I
mpa
ct
Catastrophic
100
Low
(100X1=100)
Medium
(100X3=300)
Medium
(100X10=1000)
High
(100X30=3000)
High
(100X100=10000)
Serious
30
Low
(30X1=30)
Low
(30X3=90)
Medium
(30X10=300)
High
(30X30=900)
High
(30X100=3000)
Moderate
10
Low
(10X1=10)
Low
(10X3=30)
Low
(10X10=100)
Medium
(10X30=300)
Medium
(10X100=1000)
Minor
3
Low
(3X1=3)
Low
(3X3=9)
Low
(3X10=30)
Low
(3X30=90)
Medium
(3X100=300)
Low
1
Low
(1X1=1)
Low
(1X3=3)
Low
(1X10=10)
Low
(1X30=30)
Low
(1X100=100)
1
3
10
30
100
Rare
Unlikely
Possible
Likely
Almost certain
Probability/ Likelihood
43
C.1.5 Health and safety Worksheets Health and Safety
Sample receiving
Function Activity Occupation Task Inherent likelihoo
d Inherent
consequence Inherent
risk rating Residual likelihood
Residual consequence
Residual risk rating Risk Controls
Sample receiving Offloading Sample
Receiver
Physical offloading of
samples 3 3 9 1 1 1
Personal injury, Loss of samples
PPE, SOP
Visual inspection
Sample Receiver
Inspecting sample bags
10 10 100 3 10 30
Counting of samples
10 30 300 1 3 3
Correlation Sample Receiver
Checking paper work against the physical samples in presence of Customer
10 30 300 1 30 30
Creating a worksheet on
the LIMS system 10 10 100 1 10 10
Record and rectify any discrepancies
10 10 100 1 10 10
44
Bulk sample preparation
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Bulk sample prep.
Crushing Crusher Operator
Reduce size of rock
30 10 300 3 10 30
FB in eye, personal injury
PPE, SOP
Collecting of crushed rock
10 30 300 3 10 30
Splitting/ Riffling
Crusher Operator
Reduce the mass of crushed
rock 10 10 100 3 3 9
FB in eye, personal injury
PPE, SOP
Collecting of crushed rock
10 30 300 3 10 30
Correlation Section Leader
Logging of sample ID's
10 10 100 3 10 30
Record and rectify any discrepancies
10 30 300 3 10 30
Transfer to next section
Crusher Operator
Physical movement of
prepared samples to the
drying area
10 10 100 3 10 30
Slip & fall, falling objects
PPE, SOP
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system, SOP
45
Sample preparation
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Sample prep.
Transferring sample from received packet into sample dish
Lab. Operator
Emptying of sample packet into sample dish
3 30 90 3 30 90
Ensure ticket remains with sample
10 30 300 3 30 90
Drying samples
Lab. Operator
Placing the dish and sample into the drying facility
3 10 30 1 10 10
Burning
PPE, Gloves - heat resistant
Ensure the sample is fully dried
10 3 30 3 3 9
Recording sample ID onto sample packet
Lab. Operator
Writing sample ID onto brown paper bag
10 3 30 1 3 3
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system, SOP
Record and rectify any discrepancies
10 30 300 3 10 30
46
Crushing
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Crushing Crushing Crusher Operator
Reduce size of rock
30 10 300 3 10 30
FB in eye, personal
injury
PPE, SOP
Collecting of crushed rock
10 30 300 3 10 30
Splitting/ Riffling Crusher Operator
Reduce the mass of
crushed rock 10 10 100 3 3 9
Collecting of crushed rock
10 30 300 3 10 30
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust
extraction system,
SOP
Record and rectify any discrepancies
10 30 300 3 10 30
47
Pulverising
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Pulverising Pulverising Crusher Operator
Placing sample into Pulveriser
3 30 90 1 10 10
Collects
pulverised material
10 30 300 3 10 30
Check whether pulverised
material is of the correct fineness
10 10 100 3 3 9
Place new discs in Pulveriser if
necessary 10 10 100 3 3 9
Hand injuries SOP, PPE
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system,
SOP
Record and rectify any discrepancies
10 30 300 3 10 30
48
Batching
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk rating Risk Controls
Batching Sorting of samples Batcher
Numerical sorting of packets
10 10 100 3 10 30
Physical inspection of sample ID's
10 3 30 3 3 9
Preparation of batch Batcher
Placing the sorted packets into trays according to the worksheets created at sample receiving
3 30 90 1 10 10
Record and rectify any discrepancies
10 30 300 3 10 30
Transferring
of the batch to fluxing
Batcher Physical placement of tray at fluxing
3 30 90 1 10 10
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system, SOP
49
Fluxing
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Fluxing Preparation of furnace tray
Fluxer Physical inspection of crucibles
10 10 100 3 10 30
Hand injuries PPE, SOP
Correlation of tray against worksheet
3 30 90 1 10 10
Addition of flux mixture to crucibles
3 30 90 1 3 3
Dust and lead
Dust extractor, PPE, SOP
Weighing of samples Fluxer
Transfer of sample aliquot to crucibles as per worksheet
3 10 30 1 3 3
Capturing of sample on LIMS
3 10 30 1 3 3
Mixing of material in crucible
3 3 9 1 1 1
Dust and lead
Dust extractor, PPE, SOP
Addition of silver 3 10 30 1 3 3
Coppering of tray for tray ID purposes
3 10 30 3 3 9
50
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Transfer of furnace tray to Furnace Room
Fluxer Physical placement of tray at furnaces
3 10 30 1 3 3
Slipping and falling
PPE, SOP
Completing worksheet
10 3 30 3 1 3
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system, SOP
Record and rectify any discrepancies
10 30 300 3 10 30
51
Furnaces
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Furnaces Loading Furnace Operator
Physical inspection of tray against worksheet
10 10 100 3 3 9
Preparation of furnace before loading
10 10 100 3 3 9
Respiratory problems and contamination
PPE, Dust extraction system, SOP
Placing of crucibles in furnace
10 10 100 3 3 9
Contamination, Burning PPE, SOP
Inspection of fusion process
10 10 100 3 3 9 Burning PPE, SOP
Recording of fusion process
3 3 9 1 1 1
Preparation of receiving moulds
3 3 9 1 1 1
Contamination, Burning, Falling objects
PPE, SOP
Unloading Furnace Operator
Determine fusion is complete
10 10 100 3 3 9
Burning PPE, SOP
Pouring of the fused material
10 30 300 3 10 30
Contamination, Burning, Falling objects
PPE, SOP
52
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Recording of process
10 10 100 3 3 9
Transfer trolley to Cupellation
3 10 30 1 3 3
Contamination, Burning, Falling objects
PPE, SOP
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system, SOP
Record and rectify any discrepancies
10 30 300 3 10 30
53
Muffle
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Muffle Muffling Furnace Operator
Deslagging of lead button from mould
10 3 30 1 1 1
Hand injuries, FB, Burning PPE,SOP
Preparation of Cupels as per worksheet from furnace room
3 10 30 1 3 3
Hammering of lead button
10 3 30 3 1 3
Hand injuries, FB, Burning PPE,SOP
Placement of lead button onto Cupel
10 30 300 3 3 9
Heat/ Burning PPE, SOP
Inspection of Cupellation process
10 3 30 3 1 3
Heat/ Burning PPE, SOP
Removal of Cupel tray after determining processes complete
10 10 100 3 3 9
Heat/ Burning PPE, SOP
54
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Correlation of worksheet against completed Cupel tray
10 10 100 3 3 9
Transfer Cupel tray to parting area
10 10 100 1 3 3
Cleaning to
prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust
extraction system,
SOP
Record and rectify any discrepancies
10 30 300 3 10 30
55
Parting
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Parting Parting Lab Analyst Correlation of worksheet against Cupel tray 10 10 100 3 3 9
Preparation of parting tray
10 3 30 3 1 3
Hammering of Prill 10 3 30 3 1 3
Transfer Prill to parting cups
10 10 100 3 3 9
Addition of parting acid 3 10 30 1 3 3 Acid burn PPE,SOP
Addition of strong acid 10 3 30 3 1 3
Washing of sample 10 10 100 3 1 3
Drying of sample 10 3 30 1 3 3 Burning PPE,SOP
Annealing of sample 3 3 9 1 1 1 Burning PPE,SOP
Completion of worksheet 10 3 30 3 1 3
Transfer of parting tray to weighing area
10 30 300 3 10 30
Cleaning to prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system, SOP
Record and rectify any discrepancies
10 30 300 3 10 30
56
Weighing
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Weighing Weighing Lab Analyst Calibration of microbalance
10 10 100 1 3 3
Inspection of parting tray against worksheet
10 3 30 1 1 1
Obtain the relevant microbalance worksheet from LIMS
10 10 100 1 3 3
Transfer sample from cup to microbalance 10 30 300 3 3 9
Record mass 10 10 100 3 3 9
Print microbalance worksheet
10 10 100 1 3 3
Correlate microbalance worksheet to worksheet
10 10 100 1 3 3
57
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Record and rectify any discrepancies
10 30 300 3 10 30
Attach microbalance worksheet to worksheet
3 10 30 1 3 3
Transfer completed document to reporting office
3 10 30 1 3 3
Cleaning to prevent contamination
10 10 100 3 10 30
Dust
PPE, Dust extraction system, SOP
58
Reporting
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Reporting Data capturing Data Capturer Preparation of
report sheet 3 10 30 1 3 3
Correlation of microbalance sheet, worksheet and request sheet
3 30 90 1 3 3
Record and rectify any discrepancies
10 30 300 3 10 30
Protection of information
10 10 100 1 3 3
Filing of documents
3 3 9 1 1 1
Reporting Data Capturer
Ensure customer receives requested information timeously
3 10 30 1 3 3
Liaison
with customer
Data Capturer
Ensure customer is satisfied with results 3 3 9 1 1 1
Communication with customer
3 3 9 1 1 1
59
Function Activity Occupation Task Inherent likelihood
Inherent consequence
Inherent risk
rating Residual likelihood
Residual consequence
Residual risk
rating Risk Controls
Director Providing consultation to customer
3 3 9 1 1 1
60
Organisational strategy
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
Appendices Baseline Risk Assessment attendance list
No. Initials &
Surname Occupation Qualification & experience
1
K.B Gibbons Director *National diploma in Analytical Chemistry. *Government Assayer Certificate of Competency. *Chemical Laboratory since 1982 to present.
2
B. Nyai Chemist *Trained at Mintek (in-house certificates) *Chemical and Metallurgical Laboratory since 1985 to present.
3
B. Kok Financial and HR Administrator
*B.Sc degree (1999 UNISA) *Final year B.Com Management Accounting student at UNISA *Chemical Laboratory since 1999 to present.
4
Health, Safety and Risk Consultants
Astral Risk management
46 years Mining, Safety, Risk management, BTech degree in Health and Safety Management, Masters degree in Risk Management
5
Super laboratory employees
As per occupation list
As per training section in document
76
D. References
No. Reference 1 http://www.acts.co.za 2 Purdy, G. (1987). Systematic cause analysis technique: DNV, IRCA. 3 Haasbroek, D. (1998). Executive Safety/ Risk Management orientation: IRCA. 4 Rawson, C. (1988). Risk screening. Oracle Services [Article online]. Retrieved November
12, 2005 from the World Wide Web: http://www.oracle-services.com.au/risk_screening.htm.
5 5. "Process Hazard Analysis." Safety Management Services: Risk Matrix. 20 Nov. 2005,
http://www.sms-ink.com/services_pha_matrix.html. 6 Lihou, M (2002). Hazard and Operability studies 1. Lihou Technical & Software Services
[Article Online]. Retrieved November 10 2005 from the World Wide Web: http://www.lihoutech.com/hzp1frm.htm.
7 Lihou, M (2002). Hazard and Operability studies 2. Lihou Technical & Software Services
[Article Online]. Retrieved November 10 2005 from the World Wide Web: http://www.lihoutech.com/hzp2frm.htm.
8 Haasbroek, D. (1998). Principles of risk assessment: IRCA. Randfontein: James Park. 9 Management and Organisation Behaviour 5th edition By Laurie J. Mullins.
10 Risk Management and Risk Assessment by International Risk Control [IRCA]- Haasbroek, D.
11 Mining, Engineering and Risk Consultants contracted in.
12 Super Laboratory Services records and reports.
13 Current employees Super Laboratory Services