Step-by-Step Guide on Risk Management For Metalworking Sector.

Step-by-Step Guide on Risk Management

For Metalworking Sector

For Metalworking Sector

Legends

Objectives

Risk Management RegulationsOverview of Risk Management

Roles and Responsibilities

Risk Management Process

References

Contents

Note: Please click ( ) on the individual tab for more information

Risk Management (RM) Leader RM Members RM Team

RA TeamRisk Assessment (RA)

Leader RA Members

Samples Forms Video Clips

Legends

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• This Guide aims to provide basic guidance in implementing risk management (RM) at workplaces.

• Potential incidents can be prevented when hazards are identified and risks are managed.

Objectives


• The WSH (Risk Management) Regulations is one of the key components of the Workplace Safety and Health (WSH) Act.

• Under the Regulations, all workplaces are required to conduct risk assessments for routine and non-routine work.

Risk Management Regulations


Risk Management involves

• identifying and analysing safety and health hazards associated with work;

• assessing the risks involved;

• prioritising measures to control the hazards and reduce the risks;

• controlling and monitoring the risks; and

• communicating these risks to all affected persons.

Overview of Risk Management


Roles and Responsibilities

Employer

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Roles and Responsibilities of an Employer

TASK DETAILS

Risk Control Measures (RCM)

Require all reasonably practicable steps to be taken to eliminate/minimize any foreseeable risk

Require RCM to be implemented according to the hierarchy of control

Support the implementation of RCM

Risk Register Require Risk Register to be updated and available at all time

RA Records Ensure RA records are kept for 3 years from the approval date

Contractors / suppliers

Require contractors / suppliers to conduct RA and implement risk control measures for work carried out by them at the workplace

Employer

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Manager

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Roles and Responsibilities of a Manager

TASK DETAILS


Prepare an action plan to implement RCM Ensure RCM are carried out and monitor their

effectiveness Ensure safe work procedures (SWP) are available

for all operations and implemented Review RA if the RCM are inadequate and

ineffective

Risk Register Ensure risk register is updated and available at all time

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Manager

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Manager

Roles and Responsibilities of an Employee

TASK DETAILS

Risk Assessment (RA)

Understand the hazards and possible injury / ill-health for carrying out activities assigned to him


Comply with all risk control measures Adhere to safe work procedures established at the

workplace

Communication

Inform Manager of :

- new hazards / risks and ways to reduce hazards / risks, or

- any shortcomings in the safe work procedures or risk control measures

Report any unsafe behaviour of other workers


Employee

I. Must be Available upon RequestII.Keep for at least 3 years

I. Must be Available upon RequestII.Keep for at least 3 years

Record-keeping

I. Form TeamII.Identify Tasks of Each Process III.Gather Relevant Information

I. Form TeamII.Identify Tasks of Each Process III.Gather Relevant Information

Preparation

I. Obtain Employer / Management Approval

II. Communicate the Hazards and their Controls

III.Implement Control Measures IV.Audit / Regular InspectionsV. Review RA on a Regular Basis



III.Implement Control Measures IV.Audit / Regular InspectionsV. Review RA on a Regular Basis

Implementation

and Review

I. Hazard IdentificationII.Risk EvaluationIII.Risk Control


Risk Assessment

Risk Management Process

1

2

3

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I. Form Team

A. Appointment of RM Team

A1. Employer to:

• Appoint a RM Leader

• Appoint RM Members

• Ensure RM Team is trained and competent in risk management

• Engage RM Consultant to assist RM Team if further assistance is required

I. Form TeamII.Identify Tasks of Each

Process III.Gather Relevant

Information



Information

Preparation1

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A2. Prerequisite and Roles of a:

Prerequisite

• Senior member of the workplace

• Good knowledge of work activities

• Competent in RM

• Attended a RM course

Roles

• Lead and coordinate RM implementation

• Provide RA updates and risk control measures to employer

• Obtain approval from Employer / Manager for the implementation of risk control measures

RM Lead

er



Information



Information

Preparation1

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Information



Information

Preparation1

Prerequisite

• Good knowledge of work activities

• Competent in RM

• Attended a RM course

RM Members

A3. Prerequisite and Composition of :

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Information



Information

Preparation1

A4. Main Function of RM Team:

RM Leader

RM Members

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Information



Information

Preparation1

B. Appointment of RA Team

B1. RM Team to:

• Appoint RA Leaders among the RM Members

• Assist RA Leaders if further assistance is needed

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Information



Information

Preparation1

B2. Prerequisite and Roles of a :

Prerequisite

• A member of RM Team

Roles

• Form RA Team

• Lead and co-ordinate RA implementation

• Provide update to RM Team on RA implementation and risk control measures

RA Lead

er

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Information



Information

Preparation1

RA Membe

rs

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Prerequisite

• Good knowledge of the work activities

Composition

• Comprise staff/workers involved in the work, as well as contractors, suppliers and other persons who are familiar with the work

B3. Prerequisite and Composition of :



Information



Information

Preparation1

Function

• Conduct RA within the areas assigned by RM Team

• Determine if the hazards could bring harm beyond their work area

• Prepare Inventory of Work Activities

RA Leader

RA Members

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B4. Main Function of RA Team

Note: A RM Member is not necessary a RA Leader



Information



Information

Preparation1

Relationship between RM Team and RA Team

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RA Team

RM Team

RA Team

RA Leader who is

also a RM Member

RA Leader who is also a RM Member



Information



Information

Preparation1

II. Identify Tasks of Each Process

A. RM Team to set RA scope

• Divide the workplace into few a distinct areas

• Assign RA Team for each distinct area

B. RA Team to prepare Inventory of Work Activity (IWA)

• Prepare IWA form for area(s) assigned by RM Team

• IWA form to include activity inventory, location, process and activity

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III.Gather Relevant Information

A. RM Team to gather information related to RM scoping :

• Workplace layout plan

• Process or work flowchart

• List of work activities in the process



Information



Information

Preparation1

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Information



Information

Preparation1

Note: The above information ONLY serve as a guide 25/50

B. RA Teams to gather information on RA process :

• List of tools, machinery and chemicals used• Records of past incidents & accidents• Observations, interviews and feedback on WSH related matters • WSH inspection records and audit reports • Manufacturer’s instruction manual including safety data sheets • Relevant legislation, Codes of Practice and specifications• Details of existing risk control measures • Safe work procedures • Copies of previous RA• Medical records of workers



Risk

Assessment2

Risk Assessment is a process of :

• Identifying and analysing safety and health hazards associated with work;

• Assessing the risks involved; and

• Prioritising measures to control the hazards and reduce the risks

Risk Assessment must be available for all work activities

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I. Hazard Identification

A. What is a Hazard ?

• Anything, any source or any situation with the potential to cause bodily injury or ill-health



Risk

Assessment2

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Risk Assessment Form Department: RA Leaders: Approved by:

Signature:

Reference Number:

Process: RA Member 1: Process / Activity Location: RA Member 2: Original Assessment Date: RA Member 3: Name:

Last review Date: RA Member 4: Designation: Next review Date: RA Member 5: Date:

Hazard Identification Risk Evaluation Risk Control

Ref Work

Activity Hazard

Possible Injury / Ill-

health

Existing Risk Controls

S L RPN Additional Controls

S L RPN Implementation

Person Due Date

Remarks

B. How to Identify Hazard?

B1. RA Leader to determine ways to identify hazards

• brainstorming

• process review

B2. RA Team to determine sources of hazards

• physical

• mechanical

• electrical

B3. RA Team to consider if the hazards could cause harm beyond their immediate area of work



Risk

Assessment2

• chemical

• biological

• others

• process hazard analysis

• job safety analysis

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C. How to Identify Risk?

C1. List all work activities from the Inventory of Work Activities (IWA) form in the ‘Work Activity’ column



Risk

Assessment2

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Risk Assessment Form Department: Warehouse RA Leaders: Mr Alan Lee Approved by:

Signature:

Reference Number: Warehouse 0001

Process: A) Receiving of Raw Materials RA Member 1: Mr Tan Meng Chin Process / Activity Location: Entrance Gate 1 RA Member 2: Ms Alice Ng Original Assessment Date: 05 May 2009 RA Member 3: Mr Abdul Rahman Name: Mr James Chan

Last review Date: 05 June 2009 RA Member 4: Mr Sazali Mohd Designation: Warehouse Manager Next review Date: 05 June 2012 RA Member 5: Mr Veerasamy Date: 05 June 2009


Ref Work

Activity Hazard


health




Person Due Date

Remarks

A1. Forklift operation

A2. Mechanical Lifting using crane

A3. Manual Lifting

C2. List all hazards for each work activity in the ‘Hazard’ column



Risk

Assessment2

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Signature:





Ref Work

Activity Hazard


health




Person Due Date

Remarks


Moving forklift collide with other vehicles, pedestrians, parts or equipment due to speeding

Moving forklift collide with other vehicles, pedestrians, parts or equipment due to misuse



Risk

Assessment2

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Signature:





Ref Work

Activity Hazard


health




Person Due Date

Remarks



Injury to forklift operator or co-workers

Fatality to forklift operator or co-workers

C3. List all possible injuries / ill-health in the ‘Possible Injury /

Ill-health’ column

II. Risk Evaluation

A. What is a Risk?

• The likelihood that a hazard will cause a specific bodily injury to any person



Risk

Assessment2

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Signature:

Reference Number:




Ref Work

Activity Hazard


health




Person Due Date

Remarks



Risk

Assessment2

B. How to Evaluate Risk?

B1. List all existing control measures for each injury / ill-health in the ‘Existing Risk Controls’ column

Risk Assessment Form

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Department: Warehouse RA Leaders: Mr Alan Lee Approved by: Signature:





Ref Work

Activity Hazard


health




Person Due Date

Remarks




Display speed limit sign





Risk

Assessment2

B2.Rate the most likely severity outcome of the injury in the ‘S’ column

B3. Rate the likelihood that the hazard may cause the injury/ill-health in the ‘L’ column

B4. Multiply the ‘S’ and ‘L’ columns in the Risk Prioritisation Number (RPN) column


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Ref Work

Activity Hazard


health




Person Due Date

Remarks





4 2 8



5 2 10






Ref Work

Activity Hazard


health




Person Due Date

Remarks





4 2 8



5 2 10



Risk

Assessment2

B5. Compare the ‘RPN’ against the Risk Matrix

B6. RA Team to take action according to the recommended actions based on the current risk level


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Risk Evaluation based on Code of Practice on Risk Management (1 of 2)



Risk

Assessment2

Severity Scoring

(‘S’ column)

Likelihood Scoring

(‘L’ column)

Classification of Risk (Risk Matrix)

(‘RPN’ column)

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Risk

Assessment2

Risk Matrix

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Risk Evaluation based on Code of Practice on Risk Management (2 of 2)

III.Risk Control

A. What is Additional Risk Control?

• To eliminate, reduce or confine the risk to an acceptable level



Risk

Assessment2

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Signature:

Reference Number:




Ref Work

Activity Hazard


health




Person Due Date

Remarks

B. How to Control Risk?



Risk

Assessment2

B1. Consider more effective measures in the hierarchy of control

ELIMINATION

PERSONAL PROTECTIVE EQUIPMENT

SUBSTITUTION

ENGINEERING CONTROLS

ADMINISTRATIVE CONTROLS

Most Effectiv

e

Least Effectiv

e

Change the Work Process

Provide Hearing Protectors

Replace Metal Gears with Pulley with Belt

Implement Noisy Machine Enclosure

Implement Work Rotation

Hierarchy of Control Examples for Noise Control 39/50






Ref Work

Activity Hazard


health




Person Due Date

Remarks





4 2 8 Install speed delimiter on forklift Demarcate forklift travel path and pedestrian walkway

4 1 4




5 1 5




Risk

Assessment2

B2. List all possible controls in the ‘Additional Controls’ column

B3. Re-evaluate severity ‘S’, likelihood ‘L’ and ‘RPN’ scores(Note: New risk level should not be higher after the additional controls)

Existing risk level

New risk level

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Risk

Assessment2

B4. Identify specific person to lead the implementation of additional controls and due date

B5. Record due-date for implementation

B6. Implementation person to provide progress updates to RA Team

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Signature:





Ref Work

Activity Hazard


health




Person Due Date

Remarks






4 1 4 Mr Paul Ng (Operation Manager)

6 Jul 2009




5 1 5 Mr Paul Ng (Operation Manager)

6 Jul 2009



III. Implement Control Measures

IV.Audit / Regular InspectionsV. Review RA on a Regular

Basis





Basis


Manager to :

• Approve RA form

• Prepare an action plan to implement the measures

• Implement the recommended risk control measures

• Monitor the action plan

Implementatio

n and Review

3

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Basis





Basis

Implementatio

n and Review

3

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Manager to Inform All Persons Exposed to the Risk about :

• The nature of risks

• Any measures / safe work procedures implemented

• Means to minimise / eliminate the risks

Examples of Communication Channel :

• Toolbox meeting / briefing before the start of any work

• Video tools

Mechanical Lifting

Machine Operation Maintenance

Working in Noisy Environment





Basis





Basis

Implementatio

n and Review

3

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Basis





Basis

Implementatio

n and Review

3

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Manager to :

• Implement risk control measures

• Ensure an action plan is available, monitored and implemented (including timeline and person in charge)

• Ensure risk control measures are implemented and effective





Basis





Basis

Implementatio

n and Review

3

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IV. Audit / Regular Inspections

Manager to :

• Ensure regular inspection and audits are carried out so that the risk control measures are implemented and effective





Basis





Basis

Implementatio

n and Review

3

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V. Review RA on a Regular Basis

Manager to :

• Review / Revise RA at least once every 3 years, or

after an incident, near miss or dangerous occurrence;

a significant change in the work processes, facilities, work practices or work procedures, or change in workplace condition and layout (e.g.: introduction of new machinery, or chemicals or raw materials); or

new information on WSH risk

I. Must be Available upon Request

II.Keep for at least 3 years



Record-keeping4

I. RA Records Must be Available upon Request

Manager to :

• Ensure RA records to be readily available upon request

• RA records include:

RA forms

RA Register

Risk control measures records

Safe work procedures

Training records

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II. Keep RA Records for at least 3 years

Manager to :

• Keep all RA records for at least 3 years





Record-keeping4


• Workplace Safety and Health Act

• Workplace Safety and Health (Risk Management) Regulations

• Code of Practice on Workplace Safety and Health (WSH) Risk Management

• Workplace Safety and Health Council http://www.wshc.sg

• Ministry of Manpower http://www.mom.gov.sg

References


Step-by-Step Guide on Risk Management For Metalworking Sector.

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