How can you identify common safety and risk hazards in your manufacturing operations?

1 Hazard Identification

The initial step in identifying hazards present or that could arise in your manufacturing operations is to inspect the workplace, observe activities, equipment, and materials. Additionally, you should review records of past incidents, near misses, complaints, and audits. To further your understanding of potential sources of harm, consult with workers, supervisors, customers, suppliers, and regulators. Additionally, you should analyze tasks, processes, and procedures and research best practices, standards, and regulations for your industry and sector. All of these techniques can help you identify hazards such as chemicals, electricity, machinery, noise, fire or human error.

2 Risk Assessment

The next step is to assess the risk level of each hazard. Risk is the likelihood and severity of harm that a hazard can cause. You can use a risk matrix to evaluate the risk level based on two factors: the probability of occurrence and the impact of consequence. For example, a hazard that has a high probability of occurrence and a high impact of consequence would have a very high risk level, while a hazard that has a low probability of occurrence and a low impact of consequence would have a very low risk level. You can assign numerical or qualitative values to each factor and calculate the risk score for each hazard.

3 Risk Control

The third step is to control the risk of each hazard by applying the hierarchy of controls, a framework that prioritizes the most effective and feasible ways to eliminate or reduce the risk. The hierarchy consists of five levels, beginning with elimination, which entails removing the hazard completely from the workplace. Substitution involves replacing the hazard with a less harmful alternative. Engineering focuses on designing or modifying the equipment, process, or environment to isolate or minimize the hazard. Administrative controls involve implementing policies, procedures, training, or supervision to reduce exposure or frequency of the hazard. Lastly, personal protective equipment (PPE) involves providing or wearing appropriate clothing, gloves, masks, goggles, or other devices to protect against the hazard. It is important to always try to apply the highest level of control possible and use a combination of controls if necessary.

4 Risk Monitoring

The fourth step is to monitor the risk of each hazard by measuring and evaluating the effectiveness and performance of the controls. You can use different methods to do this, such as conducting regular inspections, audits, and reviews of the workplace; collecting and analyzing data on incidents, near misses, injuries, illnesses, and losses; seeking feedback from your workers, supervisors, customers, suppliers, and regulators; comparing your results with your goals, objectives, indicators, and benchmarks; and identifying any gaps, weaknesses, or opportunities for improvement. Monitoring the risk in this way will help you ensure that you are taking the necessary steps to keep your workplace safe.

5 Risk Communication

The fifth step is to communicate the risk of each hazard by informing and engaging stakeholders about the hazards, the controls, the monitoring, and the improvement actions. You can use various channels and formats to communicate the risk, such as providing clear signs, labels, instructions, and warnings; delivering relevant training and education programs; reporting and disclosing risk information; sharing best practices with peers; and encouraging a positive safety culture. By following these five steps, you can identify and manage common safety hazards in manufacturing operations. This will help protect workers, customers, assets, reputation, and profitability while complying with legal and ethical obligations.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?