Doc No:MS/EMS/R/17

#VALUE! HAZARD IDENTIFICATION AND RISK ASSESSMENT Rev No: 00

Rev Date: 01-12-2024

Base Risk Analysis Current Controls : Risk Analysis with controls

Elimination/
Normal /
Sr. Operation / Routine / Applicable Legal/other Risk Acceptable/ Substitution/Engineering Normal / Abnormal/ Risk Acceptable/
Sub- Activity Abnormal/ Hazard / Concern Risk/ Consequence Remarks
No. Activity Non routine requirement Legislati Consequ Likeliho Value Unacceptable control/ Administrative Emergency Legislati Consequ Likeliho Value Unacceptable
Emergency
on ence od control/ Personal Protective on ence od
Equipment

- Machine guards and safety

barriers
Pinch points, crush
Machine Operating Routine Normal No Mechanical hazards 1 2 3 6 Acceptable - Emergency stop buttons N 1 2 2 4 Acceptable
injuries, entanglement
- Operator training on safe
handling

- Insulated wiring
Injection Electric shock, short
1 Electrical Maintenanace Routine Normal NO Electrical hazards 2 2 1 4 Acceptable - Regular maintenance N 2 1 1 2 Acceptable
Moulding circuits
- Emergency cut-off switches

- Use of heat-resistant gloves

Burns from molten
- Warning signage near hot
Heating Routine N No Heat Hazard material, hot machine 1 2 2 4 Acceptable N 1 2 1 2 Acceptable
surfaces
parts
- Temperature monitoring

1. Follow strictly the working

Burns from molten
instructions
Material Handling Routine N No Heat Hazard material, hot machine 1 2 3 6 Acceptable N 1 2 2 4 Acceptable
2. Personal Protective
parts
Equipment
- Insulated wiring
Raw Material Electric shock, short
Electrical Maintenanace Routine Normal NO Electrical hazards 1 2 4 8 Acceptable - Regular maintenance N 1 2 2 4 Acceptable
2 Preheating & circuits
- Emergency cut-off switches
Post Curing
- Use of heat-resistant gloves
Respiratory issues, - Warning signage near hot
Preheating Routine Normal NO Fume emissions 1 2 2 4 Acceptable
toxic inhalation surfaces
- Temperature monitoring

Working On Electric Proper trained employee &

N/R E No Electrical Shock Body Injury 1 3 1 3 Acceptable N 1 2 1 2 Acceptable
Panel PPE
Checking of electrical
current of motor & other Proper trained employee &
R E No Electrical Shock Body Injury 1 3 4 12 Unacceptable A 1 2 4 8 Acceptable
devices.(working on live PPE
electrical panels)

Check & clean all

Proper trained employee &
Electrical panels N/R N No Electrical Shock Body Injury 1 2 2 4 Acceptable N 1 1 2 2 Acceptable
PPE
throughly.
Checking all earth
Electrical Mechnical Hazard / Proper trained employee &
3 connections & Earth N/R N Y Body Injury 1 2 1 2 Acceptable A 1 1 2 2 Acceptable
maintenance pits.
Electrical Shock PPE
Mainteance of HT& LT Proper trained employee &
N/R N Y Electrical shock Body Injury 1 2 1 2 Acceptable N 1 2 2 4 Acceptable
transformer PPE
Electric spark / Short Fire Hazard, Mechanical Body Injury / Burn Proper trained employee &
N/R E No 1 3 2 6 Acceptable N 1 2 2 4 Acceptable
Circuit hazards Injury PPE
Bay & street Lights Falling due to Proper trained employee &
N/R N No Body Injury 1 3 1 3 Acceptable N 1 2 1 2 Acceptable
repairing negligence,Electric Shock PPE
Noise pollution to all Proper trained employee &
To Check Noise Level N/R N No Ear injury 1 2 2 4 Acceptable N 1 2 1 2 Acceptable
employees PPE
Switching ON/OFF the Proper trained employee &
R N No Electrcal shock Body injury 1 2 1 2 Acceptable N 1 1 1 1 Acceptable
DG PPE
Proper training to all employees
Falling due to mis handling Materials get
4 Logistics Loading/Un-Loading R N No 1 4 1 4 Acceptable , N 1 2 1 2 Acceptable
of materials damage, Body injury,
administrative control
Cuts, punctures,
Deflashing Routine N No Sharp object hazards 1 3 2 6 Acceptable Proper training and PPE N 1 3 1 3 Acceptable
lacerations
Secondary - Job rotation and rest breaks
5
Process Musculoskeletal strain, - Ergonomic workstations
Visual Inspection Routine N No Repetitive motion 1 3 2 6 Acceptable N 1 3 1 3 Acceptable
fatigue - Regular training on posture
and handling
lubrication oil slipping hazard due to oil
Routine N No Body injury 1 2 3 6 Acceptable PPE N 1 1 4 4 Acceptable
replacment spillage

Working on portable
N/R N No Flying of bur, Eye injury 1 2 3 6 Acceptable PPE N 1 1 3 3 Acceptable
grinder or drilling m/c
Height Pipe line work
N/R E No Falling Hazard Body Injury 1 3 2 6 Acceptable PPE N 1 2 2 4 Acceptable
and falling on floor
Noise Hazard /elictical
6 Maintenance Working in Compressor R N No Ear injury / Shock 1 2 1 2 Acceptable PPE N 1 1 2 2 Acceptable
hazard
Water storageTank
N/R N No slippage, Body Injury 1 2 2 4 Acceptable PPE N 1 2 1 2 Acceptable
cleaning
Lifting of Machine parts
Engineering and
with crane (crane N/R N No Falling Hazard Body Injury 1 3 1 3 Acceptable N 1 2 3 6 Acceptable
Administrative control
operation)
Clean the M/c body
Flying of dust ,Inhalation of Awareness about the activity &
(inside and outside) by N/R N No Heath effect 1 2 1 2 Acceptable N 1 1 1 1 Acceptable
Dust proper PPE
Hand Blower and cloth
- Proper lifting techniques and
equipment
Crushing injuries,
R N No Mechanical hazards 1 2 1 2 Acceptable - PPE such as gloves and steel- N 1 2 1 2 Acceptable
entrapment
toe boots
- Clear work area
- Use of chemical-resistant
Tool gloves and eye protection
7 Maintenance R N Yes Chemical exposure Skin and eye irritation 2 2 1 4 Acceptable N 2 1 1 2 Acceptable
Maintenance - Proper storage of cleaning
agents

- Good housekeeping practices

- Clearly marked walkways and
R N Yes Slip/trip hazards Skin irritation 2 2 3 12 Acceptable N 2 1 2 4 Acceptable
storage areas
- Regular area inspections

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 1) legislation / Regulated:-
1 = Not regulated ie no law as of now / Regulated but complied & Within Control.
2 = Regulated ie law defined ( permitted, part of govt. mandated programme, defined regulations) but not complied.

Severity 2) Consequences 1 = Negligible ,No Injuries or minor First Aid required

2 = Marginal,Moderate, injury. Minor Medical treatment required
3 = Critical Severe injury.Extensive Medical treatment required
4 = Catastrophic Single or multiple Fatalities

Probability 3) Likelihood 1 = Very Rare / Almost impossible

2 = Remote possibility
3 = Occasional ( atleast Quarter a year)
4 = Frequent ( every week )

4.Criteria For Unacceptable Risk

1.If it is Emergency.
2.If Legislation = 2
3.If Risk Value > 8

Action is required if the cut off point crosses 12 even after control factors.
Action is required if residual risk persists to remain as emergency because of not having fool proof control.
ions) but not complied.