Unit IG2: Risk assessment Declaration: By submitting this assessment (Parts 1 – 4) for marking I declare that it is entirely my own work. I understand that falsely claiming that the work is my own is malpractice and can lead to NEBOSH imposing severe penalties (see the NEBOSH Malpractice Policy for further information). Important note: You must refer to the document ‘Unit IG2: risk assessment – Guidance and information for learners and Learning Partners’ while completing all parts of this assessment. Your Learning Partner should provide you with a copy, but it can also be downloaded from the relevant resources section for this qualification on the NEBOSH website. Part 1: Background You should aim to complete this section in 150 - 200 words. Topic Comments Name of organisation* Ansari Sugar Mills Limited Site location* Hyderabad, Pakistan Number of workers 700 On July 9, 1989, Ansari Sugar Mills Limited was established in Pakistan as a public limited company. They sustain contribution to the National Economy by producing the cost effective product. The goal of Ansari Sugar Mills Limited is to establish an International Standard product as a brand that is recognized globally. Their main product is white refined sugar, and bi products are molassess, bagasse, sugarcane press mud, and these are used in the manufacturing of other products. Raw material mainly used sugar beets or sugar cane. During visit I notice following activities crushing, milling, weighing, crystallization, filtration, and centrifugation and in machinery General description of the organisation maintenance tasks such as electrical work, welding, and painting on machines. Conveyors, boilers, juice strainers, shredding, sieving, jaw crushers, and filtering machines are among the heavy machinery that power the plant. There are two shifts at the plant, each lasting eight hours. The first shift begins at 8:00 am and ends at 4:00 pm, with the second shift beginning at 4:00 pm and ending at 12:00 am. Young, invigorating workers make up the workforce, and female employees can also be found in administrative roles. I included many areas in my risk assessment like crushing area, shredding area, sugar cane Description of the area to be included in the storage area, juice processing area, boiler hall, power generation section, admin areas, security risk assessment areas, admin areas, CCR rooms, electrical workshop and ,mechanical workshop etc Any other relevant information HSE manager who reports directly to finance director will be the most responsible person for Learner number: Learner name: Page 1 of 15 managing health and safety in this plant. * If you’re worried about confidentiality, you can invent a false name and location for your organisation but, all other information provided must be factual. You should aim to complete this section in 100 - 200 words. Note: this section can be completed after you have competed your risk assessment. Outline how the risk assessment was carried Before conducting my risk assessment task I studied the ig2 book of RRC international which out this should include: helped me a lot to understand the hazard identification and their control measures. I also visited international labour organization websites, which helped me a lot to understand the health and sources of information consulted; safety codes and conducts of the chemical plant. I also visited UK base websites to understand the who you spoke to; and health and safety requirements of the sugar manufacturing plant. These websites are given below how you identified: http://www.hse.gov.uk/pubns/priced/hsg261.pdfhttps://www.hse.gov.uk/toolbox/machinery/index.htm - the hazards; and https://www.ilo.org/global/topics/safety-and-health-at-work/industries- what is already being done; and sectors/WCMS_219022/lang--en/index.htm - any additional controls/actions that After studying these websites and materials I visited plant site for the physical inspection of site may be required. where I talked to the workers, operators, engineers, foremen and technicians. All the workers had a wide experience of workplace hazards and their control measures and which control measures are required. HSE manager also helped me to complete my risk assessment. He gave me all the records of accidents, incidents and investigations which helped me to understand the workplace hazards and their control measures. Following my inspection I referred back to the notes that I have made during my inspection to decide on which further control measures are required I also referred some HSE notes on codes and conduct for example for fire safety I referred http://www.hse.gov.uk/pubns/eh44.pd Part 2: Risk Assessment Organisation name: Ansari Sugar Mills Limited Date of assessment: November 2, 2023 Scope of risk assessment: crushing area, shredding area, sugar cane storage area, juice processing area, boiler hall, power generation section, admin areas, security areas, admin areas, CCR rooms, electrical workshop and ,mechanical workshop etc Learner number: Learner name: Page 2 of 15 Hazard category and hazard Who might be harmed and how? What are you already doing? Fire All the workers, supervisor and engineers that are working on the plant can be harmed. The spark form any faulty equipment or any unattended cigarette bud can get contact with the fuels and flammable substance and a big fire accident can occur due to which the workers can get burn injuries if they are caught in the fire, they can be trapped in the building or inhaling problems to them can also occur. Firefighting training held by the fire department at regular basic Fire extinguisher at different places. Smoking, faulty electrical equipment, handling fuels and other flammable substances etc. Hazardous substance High concentration of bagasse dust in the production hall All the workers working in the production hall can be harmed There was high concentration of the bagasse dust and the workers working in the production hall are exposed to this hazardous dust. The workers exposed to this Learner number: Dust mast were given to the workers The workers were given necessary training and instruction. Learner name: What further controls/actions are required? 1. Routinely inspection and maintenance of electrical equipment must be done to prevent faults. 2. Smoking area must be designated separately 3. Replacement or purchasing of the low-quality electrical wire with standard quality wire to reduce the fire chances. 4. Storage of flammable liquid should be away from production area 5. Safety sign to control fire must be available at the production department. 6. Hot work activities must be under permit to work system. 1. Install local exhaust ventilation system in the production hall. 2. Install dust collectors on different spots in the production halls 3. All the parts of the ventilation system must be inspected and maintained. 4. Provide health surveillance to the workers periodically 5. Give job rotation and rest Timescales Responsible for further person’s job title actions to be completed (within …) 1 month Electrical Engineer 2 months Plant Manager 3 months Finance Manager 1 Month Plant Manager 1 week Operation Manager 2 weeks HSE supervisor 2 month Finance Manager 1 month Finance Manager 1 week HSE officer 3 months Finance Manager 2 weeks HR Manager Page 3 of 15 Hazard category and hazard Who might be harmed and how? What are you already doing? dust can get irritation in eyes, inhaling problems like asthma and lungs cancer etc. Vibration Excessive vibration during crushing and shredding activities Work equipment and machinery Dangerous parts of the All the workers that are working in crushing and shredding areas can be harmed The workers were exposed to high vibration in crushing and shredding areas and exposure to this high level of vibration for a long period of time in the workers can create many physical problems in the workers like whole body vibration syndrome, joint damage, joint pain and muscle pain etc. All the workers that working near pressing machines can be harmed. The workers working around the machinery can get contact with the Learner number: What further controls/actions are required? breaks to the workers. 6. Provide workers with Timescales for further actions to be completed (within …) Responsible person’s job title 1 month Plant Manager 1 month Plant Manager 2 month Mechanical Engineer 1 month Maintenance staff 3 month Finance Manager 2 week HR Manager 1 month Finance Manager 1 week HSE supervisor 4 days Plant manager changing and washing facilities. Anti-vibration PPEs are provided to workers. 1. Vibration absorber foams should be used to reduce vibration intensity. 2. Mechanically isolation of vibration parts or surface to reduce exposure. 3. Proper maintenance of equipment should be conducted to avoid excessive vibration. 4. Health surveillance system of workers exposed to higher vibration should be established. 5. Job rotation for workers expose to long term exposure of vibration. Information and training was given to the workers. Emergency stop buttons were installed. Learner name: 1. Safety guard must be installed around the dangerous parts of the machines. 2. Precaution methods and safety signs must be installed in the area. 3. Tool box talk about machine Page 4 of 15 Hazard category and hazard Who might be harmed and how? crushing machines were naked moving parts of the machinery and they can get many injuries like cuts, sprains and bruises and the in severe condition their body parts can also damage and the bone fracture can also happen. worker working in a confined space can get harmed. While cleaning storage tanks, it can be harmful to workers due to lack of ventilation system and workers will sweat a lot. There was a huge chance that workers would become unconscious, hypoxia, excessive heat If an emergency arises, it can lead to coma, drowning, suffocation or even death. Confined Space Cleaning of the storage tank. Learner number: What are you already doing? What further controls/actions are required? hazard must be conducted. 4. Install tripping devices on the machines 5. Workers must be supervised while working with machinery. Provision of safety helmets, safety shoes, safety jackets Toolbox talks were conducted before work. Learner name: 1. Ensure proper ventilation and exhaust system 2. Proper oxygen level should be maintained inside a confined space 3. The space must be large enough for the worker to enter and carry out the work. 4. Appropriate gas tests should be performed before working in a confined space to detect toxic gases. 5. All the confined space activities must be under permit to work system 6. Proper information, training, Timescales for further actions to be completed (within …) Responsible person’s job title 1 month Finance Manager 1 week Plant manager 1 week Finance Manager 1 week Mechanical Engineer 1 week Plant manager 5 days Mechanical Engineer 1 month Plant manager 1 week HSE supervisor and supervision should be provided to workers. Page 5 of 15 Hazard category and hazard Who might be harmed and how? What are you already doing? What further controls/actions are required? Noise The workers working in high noise producing areas can be harmed. Workers were exposed to high level of noise during different machine operations. Due to which they can get many problems like ringing in ears, tinnitus, permanent hearing lose etc. Safety signs were installed. Ear protections like ear muffs were given to the workers. 1. Install silencer on different noise producing machines. 2. Give job rotation and rest breaks to the workers. 3. Proper health surveillance programme must be implemented. 4. Sound absorbing material must also be installed on different areas. 5. Proper maintenance of machines must be required. 6. Make acoustic heaven Excessive noise in the production hall due to different machine operation Timescales Responsible for further person’s job title actions to be completed (within …) 2 week Finance Manager 2 week HR Manager 3 month HSE supervisor 1 month Plant Manager 1 month Maintenance staff 1 month Plant Manager 3 weeks Finance Manager 2 weeks HR manager 2 week Plant Manager 1 week HSE supervisor around noise producing machines. Manual handling Shifting of the 50 kg heavy bags of sugar to the storage area by manually. All the workers that are involved in manual handling of the heavy sugar bags. The improper lifting posture can create many physical problems in the workers like the workers can get back pain, WRULD, muscle stretchiness and the workers can also get fatigue and stress. Learner number: Fresh water facility was available to the workers. Learner name: 1. Proper handling aids like sacks trucks and trolleys must be provided to the workers 2. Job rotations and frequent rest breaks policy should be implemented. 3. Increase the workers and there should be buddy system in the workplace to minimise the exposure of manual handling. 4. Training and consultation programme on safe lifting techniques should be provided to all workers. Page 6 of 15 Hazard category and hazard Who might be harmed and how? What are you already doing? What further controls/actions are required? 5. Energy boosting drinks Timescales Responsible for further person’s job title actions to be completed (within …) 1 week Plant Manager must be provided to the workers Movement of people and vehicles in the workplace Some vehicles were moving in the workers area like loader truck etc. All the workers at the plant site can get harmed. The moving vehicles like loader truck can get collide with the workers and they can be the cause of the many injuries like broken bone, damaged body part and worst case scenario the worker can be died also Safety signs were installed 1. Segregate the pathways for the workers and the vehicles 2. The driver of the vehicles must be given defensive training 3. There must be a traffic warden to control to the traffic management system. 4. Banksmen must be hired used while in case of reversing of the vehicles. 5. Traffic controller like speed barkers must be installed. 6. Separate parking places for 1 month Finance Manager 1 week Plant Manager 2 week HSE officer 1 week HR manager 1 month Finance Manager 1 month Finance Manager 2 week HR manager 1 week HSE supervisor 2 weeks Finance Manager 2 week Plant Manager the vehicles. Ergonomics. Constantly working on the DSE systems while the chairs were also not adjustable. All the admin workers can get harmed. The continuous work on the DSE system without any break or job rotation can be harmful for the workers the worker can get fatigue, stress, eye strain and WRULD due to the nonadjustable Learner number: N/A Learner name: 1. The workers must be given rest breaks and job rotation. 2. The worker must be given necessary welfare facilities like energy booster drinks and tea etc. 3. The chairs must be replaced with adjustable chairs. 4. The heights of the screens must also be adjustable. Page 7 of 15 Hazard category and hazard Who might be harmed and how? What are you already doing? chair of the DSE system. What further controls/actions are required? 5. The workers must be advised some physical and eye exercise. 6. Health surveillance of the Timescales Responsible for further person’s job title actions to be completed (within …) 1 week Plant Manager 3 months Finance Manager 1 month Plant Manager 1 month Plant Manager 2 weeks HSE supervisor 2 weeks HR Manager 2 months Finance Manager 1 month HSE supervisor 1 month Finance Manager 1 week Plant Manager 1 week HR Manager workers must be done. Health, welfare and work environment Extreme temperature in boiler halls All the workers working in the high temperature areas can be harmed. The workers were exposed to extreme temperature in boiler hall due to which the workers can get fatigue, heat stroke, dehydration and muscle cramps etc. Fresh water facility was available. Cooling fans were also installed at different points. 1. Provide cooling shelters and cold refugees to the workers. 2. Provide washing and bathing facilities to the workers. 3. Provide heat retardant/resistant clothing and PPE'S to the workers. 4. Provide job rotations and rest breaks to the workers. 5. Develop a good ventilation system in the workplace. Working at height Non routine painting activity with the usage of moveable ladder. The workers working on When the work is in process height can be harmed. area is barricaded for those The workers that are who are working around. involved in painting activity with the usage of moveable ladder can get fall on the floor due to the inadequate movement of the ladder and This can cause internal, external, fractures, Learner number: Learner name: 1. All the work at height activities must be under permit to work system. 2. Fixed ladder/mobile elevated working plate form should be purchased. 3. Arrange training sessions for all the workers to how to use mobile bridge. 4. Hire a Standby man which should be outside while work Page 8 of 15 Hazard category and hazard Who might be harmed and how? What are you already doing? serious injuries or even death What further controls/actions are required? is in progress. 5. Special consideration must Timescales for further actions to be completed (within …) 1 week be given to the safety harness. Learner number: Learner name: Page 9 of 15 Responsible person’s job title HSE supervisor Part 3: Prioritise 3 actions with justification for the selection Suggested word counts Moral, general legal and financial arguments for all actions: 300 to 350 words For EACH action: Specific legal arguments: 100 to 150 words Likelihood AND severity: 75 to 150 words How effective the action is likely to be in controlling the risk: 100 to 150 words Moral, general legal and financial arguments for ALL actions Moral, general legal and financial arguments Moral: Ansari Sugar Mills Limited has a moral obligation to ensure the health and safety of its workers. All of the company's workers work for a living in order to support their families. Families of workers rely largely on their daily or monthly earnings. Dependents may suffer if workplace dangers prevent a worker from returning home safely or from doing his or her job, as these effects have an adverse effect on the worker. If company is taking all necessary control measures to eliminate or reduce the risk then it may also lead toward the development of negative culture within organization. Implementation of measures which I prioritized will help to justifies moral arguments considerably. Financial: The financial burdens that an employer must face when an accident occurs at work are listed below. Therefore, the employer must implement the required measures that may be put in place to prevent the employees from becoming engaged in an accident in order to avoid these financial exemptions. If an accident occurs the will bear all the expenses of first aid treatment, hospital treatment all type of medical treatment of his workers. The premium insurance has to be paid to the insurance company would also enhance over the accident at workplace. If an accident occur at workplace, some property of the employer also damaged that would be costly for employer. When an accident occurred at workplace equipment may have to be stopped for accident investigation so the employer has to bear production losses also. Legal: Under the International Labor Organization's (ILO) Safety and Health Convention, Ansari Sugar Mills Limited is legally required to safeguard its workers (C155). Employers must follow all applicable laws and regulations. International bodies have set some standards, but if the Learner number: Learner name: Page 10 of 15 corporation fails to meet those requirements, enforcement agencies may take further action. First, they inform to organization by a notification after that they take further actions. The activity that will cause the workers harm will be avoided. Compliance agencies may even require the initiation of operations after making such adjustments or taking adequate control measures in order to reduce the risk element. In the event of a major accident the company owner can be jailed and company license can be cancelled Justification for action 1 Action (Taken from column 4 of risk assessment) Safety guard must be installed around the dangerous parts of the machines.(work equipment and machinery) The International labour organization (ILO) has also set the recommendations to develop the safe working environment at workplace. C119 - Guarding of Machinery Convention, 1963 (No. 119) states that Specific legal arguments Consideration of likelihood AND severity types of injury or ill health number of workers at risk how often the activity is carried out how widespread the risk is “The use of machinery any dangerous part of which, including the point of operation, is without appropriate guards shall be prohibited by national laws or regulations or prevented by other equally effective measures: Provided that where this prohibition cannot fully apply without preventing the use of the machinery it shall apply to the extent that the use of the machinery permits”. The likelihood of this hazard would be considered as much high because workers were working near the naked rotating parts of the crushing machines which does not have safety guard on it due to which there were many chances of the workers to be getting entangled. And the consequences of which may be in form of many injuries like cuts, bruises bone fracture etc. There are ten workers working near the rotating parts of the machine in two shifts and are at risk. The risk is associated with the crushing machines and affect workers only that are working with the machine. When considering the severity, I set 4 categories: minimal: no injury or damage occurred minor: injury requiring first-aid and/or slight damage caused to plant/equipment/buildings major: injury requiring hospital treatment/stay and/or significant damage caused to plant/equipment/buildings Catastrophic: death and/or irreparable damage to plant/equipment/buildings The severity factor would also be considered as major because this unsafe act or practice can lead to severe accident, workers can get severe injuries that should need hospital treatment. Learner number: Learner name: Page 11 of 15 How effective the action is likely to be in controlling the risk. This should include: the intended impact of the action; justification for the timescale that you indicated in your risk assessment; and whether you think the action will fully control the risk The risk associated with this work equipment and machinery hazard can be minimised by installing safety guard on the naked rotating parts of the crushing machines. The safety guard will give protection from getting entangled and the overall risk associated with this hazard will be minimised. This control action will have major impact on finance saving also because the cost of implementing this control action will be less than the cost associated with harm of the workers. I have suggested a time period of 1 month for the implementation of this control action because it will take some time to make arrangements and to get approval from the managing director I think this control action will 80 % of the risk associated with this hazard with some other control actions that are mentioned in the risk assessment section. Justification for action 2 Action (Taken from column 4 of risk assessment) Sound absorbing material must also be installed on different areas. (noise) Specific legal arguments International labour organization has made many conventions and recommendation to provide safety to the workers from noise hazard. C148 - Working Environment (Air Pollution, Noise and Vibration) Convention, 1977 (No. 148) article8 states that The competent authority shall establish criteria for determining the hazards of exposure to air pollution, noise and vibration in the working environment and, where appropriate, shall specify exposure limits on the basis of these criteria Pakistani Labour law 2005 also required that maximum controls should be implement to control the noise at the workplace. Consideration of likelihood AND severity types of injury or ill health number of workers at risk how often the activity is carried out how widespread the risk is Learner number: The likelihood associated with this hazard will be considered as high because the workers were exposed to high pitch noise and they were working in the Production area for a long period of time due to which there were number of chances that workers can get many hearing problems like tinnitus and NIHL. The current control measures were also ineffective to protect the workers from getting harm. Learner name: Page 12 of 15 There are fifteen workers working in this area in two shifts and are at risk. The risk is present in the production area and affect workers only that are working in this area. How effective the action is likely to be in controlling the risk. This should include: the intended impact of the action; justification for the timescale that you indicated in your risk assessment; and whether you think the action will fully control the risk Please see the justification 1 for severity category. The severity associated with this hazard will be considered from the above-mentioned table as major because workers will require proper hospital treatment if they get problems like tinnitus and noise induced hearing loss The risk associated with this hazard will be minimised by the Installation of Sound absorbing material in noisy areas. By this provision the noise level of the workplace will get minimised and the overall risk associated with this hazard will be minimised This control action will have major impact on finance saving also because the cost of implementing this control action will be less than the cost associated with harm of the workers. I have suggested a time period of 1 month for the implementation of this control action because it will take some time to make arrangements and to get approval from the managing director I think this control action will 80 % of the risk. Action with suitable controls can help to provide the fully control of the risk. Justification for action 3 Action (Taken from column 4 of risk assessment) All the work at height activities must be under permit to work system.(work at height) Specific legal arguments International labour organization has set many conventions and recommendation for the hazard related to work at height activities and every organization is fully bounded to comply with these conventions and recommendations. ILO Convention 1988 (C167, Article 14) (Work at height) states that Where work cannot safely be done on or from the ground or from part of a building or other permanent structure, a safe and suitable scaffold shall be provided and maintained, or other equally safe and suitable provision shall be made. In the absence of alternative safe means of access to elevated working places, suitable and sound ladders shall be provided. They shall be property secured against inadvertent movement. All scaffolds and ladders shall be constructed and used in accordance with national laws and regulations. Scaffolds shall be inspected by a competent person in such cases and at such times as shall be prescribed by national laws or regulations. Consideration of likelihood AND severity Learner number: The likelihood associated with this hazard will be considered as high because the painting workers were doing painting activity while they were standing on moveable ladder which have inadequate Learner name: Page 13 of 15 types of injury or ill health number of workers at risk how often the activity is carried out how widespread the risk is How effective the action is likely to be in controlling the risk. This should include: the intended impact of the action; justification for the timescale that you indicated in your risk assessment; and whether you think the action will fully control the risk movement also and due to which there were many chances for the workers to get fall on the floor and worker can have many injuries like head injuries, internal and external injuries and bone fracture etc.. The current control measures were also ineffective to protect the workers from getting harm. There are four workers working on height in two shifts and are at risk. The risk is present at the moveable ladder and affect workers only that are working on height using moveable ladder. Please see the justification 1 for severity category. The severity factor associate with this hazard will be considered from the above mentioned table as major because if the workers get injuries like internal and external injuries and head injuries and bone fracture they will require proper hospital treatment . The risk associated with this hazard will be minimised by applying permit to work system on all the work at height activities, this will only allow the workers to do their jobs on height with only safe working plate forms and hence the overall chances of getting fallen on the floor will be minimised This control action will have major impact on finance saving also because the cost of implementing this control action will be less than the cost associated with harm of the workers. I have suggested a time period of 1 month for the implementation of this control action because it will take some time to make arrangements and to get approval from the managing director I think this control action will 70 % of the risk associated. Action with other suitable controls can help to provide the fully control of the risk. Part 4: Review, communicate and check Suggested word counts for each section: Planned review date or period and reasoning for this: 50 - 100 words How the risk assessment findings will be communicated and who needs to know the information: 100 - 150 words Follow up on the risk assessment: 100 - 150 words. Planned review date/period with It is business policy to reassess the risk assessment with management and experts after a year. reasoning Respecting the company policy is legally required. Thus, I recommended the November 2, 2024. However, in the event of an accident or any change in working procedures, equipment, methodology, technology, standards, laws, or shift patterns, the risk assessment will also be reviewed promptly. How the risk assessment findings will be I'm going to schedule a meeting with the managing director, the allied administration, the members communicated AND who you need to tell of the health and safety committee, and the heads of the relevant sections in order to share the results of the risk assessment. I will go through all of the findings in depth in a presentation that I Learner number: Learner name: Page 14 of 15 How you will follow up on the risk assessment to check that the actions have been carried out Learner number: will give in front of them. Following the presentation, I will provide a written copy of this risk assessment to all relevant departments and members of the health and safety committee so they can take the necessary steps to execute it. Additionally, the risk assessment will be posted to the factory intranet. Finally, all employees will receive updates on additional actions and control measures using factory broadcasting means. I shall speak with the workers that are illiterate verbally. I will follow up with this risk assessment once I have successfully completed the work of communicating with all stakeholders to make sure that all recommended control measures are successfully put into place to lower the overall risk level. I will counsel them to stand out in their box and involve all pertinent stakeholders in their respective jobs. I'll let everyone use the open channel of communication to share whatever information they think might be helpful. I'll provide them the agenda items for the post-meeting and track any advancements. Following this, I'll urge them to organize more tasks and provide a detailed action plan so that the intended progress may be completed. To improve the response rate of stakeholders, I will convey all of these criteria through the appropriate channels and with the support of top management. Once feedback on this development is received, I will schedule a factory visit to verify established controls in person. I'll follow up on implemented activities in this manner. Learner name: Page 15 of 15
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