Step-by-Step Guide on Risk Management

For Metalworking Sector

Contents
Legends Objectives Risk Management Regulations Overview of Risk Management Roles and Responsibilities

Risk Management Process

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

Legends

Risk Management (RM) Leader

RM Members

RM Team

Risk Assessment (RA) Leader

RA Members

RA Team

Forms

Samples

Video Clips
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Objectives

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.

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Risk Management Regulations

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.

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Overview of Risk Management

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.

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Roles and Responsibilities

Employer
Roles and Responsibilities of an Employer
TASK Risk Assessment (RA) DETAILS Ensure RA is conducted and available for all work activities

Require RA updates to be provided in regular meetings (eg: WSH Committee Meeting)

Ensure RA is reviewed / revised at least once every 3 years, or when there is - an incident, near miss or dangerous occurrence;

- a significant change in work processes, facilities, work practices or work procedures, or change in workplace condition and layout; or
- new information on WSH risks

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Employer
Roles and Responsibilities of an Employer
TASK DETAILS Risk Control Require all reasonably practicable steps to be taken to Measures (RCM) eliminate/minimize any foreseeable risk Require RCM to be implemented according to the hierarchy of control Support the implementation of RCM Risk Register RA Records Contractors / suppliers Require Risk Register to be updated and available at all time Ensure RA records are kept for 3 years from the approval date Require contractors / suppliers to conduct RA and implement risk control measures for work carried out by them at the workplace
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Manager
Roles and Responsibilities of a Manager
TASK Risk Assessment (RA) DETAILS Ensure RA is carried out and available for all work activities

Approve RA and ensure risk level is not rated high risk

Review / Revise RA at least once every 3 years from the approval date, or when there is - 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; or - new information on WSH risk

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Manager
Roles and Responsibilities of a Manager
TASK Risk Control Measures (RCM) 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
Roles and Responsibilities of a Manager
TASK RA Records DETAILS Maintain and update RA records

Keep RA records for 3 years from the approval date

Contractors / suppliers Communication Ensure contractors / suppliers conduct RA and implement risk control measures for work carried out by them within the workplace Ensure all persons exposed to the risks are informed of : - the nature of the risks

- risk control measures

- safe work procedures

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Employee
Roles and Responsibilities of an Employee
TASK Risk Assessment (RA) Risk Control Measures (RCM) Communication DETAILS 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

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
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Risk Management Process

1 2

Preparation

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

Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

Implementation and Review

I. Obtain Employer / Management Approval II. Communicate the Hazards and their Controls III. Implement Control Measures IV. Audit / Regular Inspections V. Review RA on a Regular Basis

Record-keeping

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

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Preparation

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

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

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Preparation

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

A2. Prerequisite and Roles of a:

RM Leader

Prerequisite

Roles
Lead and coordinate RM implementation

Senior member of the workplace

Good knowledge of work activities Competent in RM Attended a RM course

Provide RA updates and risk control measures to employer

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

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Preparation

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

A3. Prerequisite and Composition of : RM Members

Prerequisite
Good knowledge of work activities Competent in RM Attended a RM course Composition Comprise staff/workers from different levels, discipline and work areas E.g.: Management staff, area manager, engineers, RA Leaders, supervisors, production operators, etc

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Preparation

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

A4. Main Function of RM Team:

RM Leader
Function Understand the workplace processes Set RM objectives Set RA boundaries, e.g.: by - department - function - work activity Assign RA Teams to conduct RA for specific areas Decide on hazards review period
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RM Members

Preparation

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

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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Preparation

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

B2. Prerequisite and Roles of a :

RA Leader

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

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Preparation

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

B3. Prerequisite and Composition of : RA Members

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

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Preparation

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

B4. Main Function of RA Team

RA Leader
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 Members
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Preparation

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

Relationship between RM Team and RA Team

RM Team

RA Leader who is also a RM Member

RA Leader who is also a RM Member

RA Team

RA Team

Note: A RM Member is not necessary a RA Leader

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Preparation

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

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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Preparation

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

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

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Preparation

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

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 Manufacturers 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
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Note: The above information ONLY serve as a guide

Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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 Assessment Form

Department: Process: Process / Activity Location: Original Assessment Date: Last review Date: Next review Date: Hazard Identification Ref Work Activity Hazard Possible Injury / Illhealth RA Leaders: RA Member 1: RA Member 2: RA Member 3: RA Member 4: RA Member 5: Risk Evaluation Existing Risk Controls S L RPN Additional Controls S Approved by: Signature: Name: Designation: Date: Risk Control L RPN Implementation Person Due Date Remarks Reference Number:

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

B. How to Identify Hazard? B1. RA Leader to determine ways to identify hazards brainstorming process review process hazard analysis job safety analysis

B2. RA Team to determine sources of hazards

physical mechanical chemical biological others

electrical

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

I. Hazard Identification II. Risk Evaluation III.Risk Control

C. How to Identify Risk? C1. List all work activities from the Inventory of Work Activities (IWA) form in the Work Activity column
Risk Assessment Form
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift operation A2. Mechanical Lifting using crane Manual Lifting Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S L RPN Implementation Person Due Date Reference Number: Warehouse 0001

Remarks

A3.

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

C2. List all hazards for each work activity in the Hazard column
Risk Assessment Form
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift Moving forklift operation collide with other vehicles, pedestrians, parts or equipment due to speeding Moving forklift collide with other vehicles, pedestrians, parts or equipment due to misuse Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S L RPN Implementation Person Due Date Reference Number: Warehouse 0001

Remarks

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

C3. List all possible injuries / ill-health in the Possible Injury / Ill-health column
Risk Assessment Form
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift Moving forklift Injury to forklift operation collide with operator or coother vehicles, workers pedestrians, parts or equipment due to speeding Fatality to forklift operator or co-workers Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S L RPN Implementation Person Due Date Reference Number: Warehouse 0001

Remarks

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

II. Risk Evaluation

A.

What is a Risk?
The likelihood that a hazard will cause a specific bodily injury to any person

Risk Assessment Form

Department: Process: Process / Activity Location: Original Assessment Date: Last review Date: Next review Date: Hazard Identification Ref Work Activity Hazard Possible Injury / Illhealth RA Leaders: RA Member 1: RA Member 2: RA Member 3: RA Member 4: RA Member 5: Risk Evaluation Existing Risk Controls S L RPN Additional Controls S Approved by: Signature: Name: Designation: Date: Risk Control L RPN Implementation Person Due Date Remarks Reference Number:

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift Moving forklift Injury to forklift Display speed operation collide with operator or co- limit sign other vehicles, workers pedestrians, parts or equipment due to speeding Fatality to Display speed forklift operator limit sign or co-workers Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S L RPN Implementation Person Due Date Reference Number: Warehouse 0001

Remarks

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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
Risk Assessment Form
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift Moving forklift Injury to forklift Display speed 4 2 8 operation collide with operator or co- limit sign other vehicles, workers pedestrians, parts or equipment due to speeding Fatality to Display speed 5 2 10 forklift operator limit sign or co-workers Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S L RPN Implementation Person Due Date Reference Number: Warehouse 0001

Remarks

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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
Risk Assessment Form
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift Moving forklift Injury to forklift Display speed 4 2 8 operation collide with operator or co- limit sign other vehicles, workers pedestrians, parts or equipment due to speeding Fatality to Display speed 5 2 10 forklift operator limit sign or co-workers Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S L RPN Implementation Person Due Date Reference Number: Warehouse 0001

Remarks

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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

Severity Scoring (S column)

Likelihood Scoring (L column)

Classification of Risk (Risk Matrix) (RPN column)

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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

Risk Matrix

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

III. Risk Control

A. What is Additional Risk Control?
To eliminate, reduce or confine the risk to an acceptable level
Department: Process: Process / Activity Location: Original Assessment Date: Last review Date: Next review Date: Hazard Identification Ref Work Activity Hazard Possible Injury / Illhealth RA Leaders: RA Member 1: RA Member 2: RA Member 3: RA Member 4: RA Member 5: Risk Evaluation Existing Risk Controls S L RPN Additional Controls S Approved by: Signature: Name: Designation: Date: Risk Control L RPN Implementation Person Due Date Remarks Reference Number:

Risk Assessment Form

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

B. How to Control Risk? B1. Consider more effective measures in the hierarchy of control
Most Effective

ELIMINATION SUBSTITUTION ENGINEERING CONTROLS ADMINISTRATIVE CONTROLS PERSONAL PROTECTIVE EQUIPMENT Hierarchy of Control

Change the Work Process Replace Metal Gears with Pulley with Belt

Implement Noisy Machine Enclosure

Implement Work Rotation Least Effective Provide Hearing Protectors Examples for Noise Control
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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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)
Risk Assessment Form
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift Moving forklift Injury to forklift Display speed 4 2 8 operation collide with operator or co- limit sign other vehicles, workers pedestrians, parts or equipment due to speeding Fatality to Display speed 5 2 10 forklift operator limit sign or co-workers Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Install speed delimiter on forklift Demarcate forklift travel path and pedestrian walkway Install speed delimiter on forklift Demarcate forklift travel path and pedestrian walkway Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S 4 L 1 RPN 4 Implementation Person Due Date Reference Number: Warehouse 0001

Remarks

Existing risk level

New risk level

5 1 5

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Risk Assessment

I. Hazard Identification II. Risk Evaluation III.Risk Control

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
Risk Assessment Form
Department: Warehouse RA Leaders: Process: A) Receiving of Raw Materials RA Member 1: Process / Activity Location: Entrance Gate 1 RA Member 2: Original Assessment Date: 05 May 2009 RA Member 3: Last review Date: 05 June 2009 RA Member 4: Next review Date: 05 June 2012 RA Member 5: Hazard Identification Risk Evaluation Possible Work Existing Risk Ref Hazard Injury / IllS L RPN Activity Controls health A1. Forklift Moving forklift Injury to forklift Display speed 4 2 8 operation collide with operator or co- limit sign other vehicles, workers pedestrians, parts or equipment due to speeding Fatality to Display speed 5 2 10 forklift operator limit sign or co-workers Mr Alan Lee Mr Tan Meng Chin Ms Alice Ng Mr Abdul Rahman Mr Sazali Mohd Mr Veerasamy Additional Controls Install speed delimiter on forklift Demarcate forklift travel path and pedestrian walkway Install speed delimiter on forklift Demarcate forklift travel path and pedestrian walkway Approved by: Signature: Name: Mr James Chan Designation: Warehouse Manager Date: 05 June 2009 Risk Control S 4 L 1 RPN 4 Implementation Person Mr Paul Ng (Operation Manager) Due Date 6 Jul 2009 Reference Number: Warehouse 0001

Remarks

Mr Paul Ng (Operation Manager)

6 Jul 2009

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I.

3
I.

Implementation and Review

II. III. IV. V.

Obtain Employer / Management Approval Communicate the Hazards and their Controls Implement Control Measures Audit / Regular Inspections Review RA on a Regular Basis

Obtain Employer / Management Approval

Manager to : Approve RA form Prepare an action plan to implement the measures Implement the recommended risk control measures Monitor the action plan

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I.

Implementation and Review

II. III. IV. V.

Obtain Employer / Management Approval Communicate the Hazards and their Controls Implement Control Measures Audit / Regular Inspections Review RA on a Regular Basis

II. Communicate the Hazards and their Controls

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

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I.

Implementation and Review

II. III. IV. V.

Obtain Employer / Management Approval Communicate the Hazards and their Controls Implement Control Measures Audit / Regular Inspections Review RA on a Regular Basis

Examples of Communication Channel : Toolbox meeting / briefing before the start of any work Video tools Mechanical Lifting Machine Operation Maintenance Working in Noisy Environment

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I.

Implementation and Review

II. III. IV. V.

Obtain Employer / Management Approval Communicate the Hazards and their Controls Implement Control Measures Audit / Regular Inspections Review RA on a Regular Basis

III. Implement Control Measures

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

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I.

Implementation and Review

II. III. IV. V.

Obtain Employer / Management Approval Communicate the Hazards and their Controls Implement Control Measures Audit / Regular Inspections Review RA on a Regular Basis

IV. Audit / Regular Inspections

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

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I.

Implementation and Review

II. III. IV. V.

Obtain Employer / Management Approval Communicate the Hazards and their Controls Implement Control Measures Audit / Regular Inspections Review RA on a Regular Basis

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
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4
I.

Recordkeeping

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

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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Recordkeeping

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

II. Keep RA Records for at least 3 years

Manager to :
Keep all RA records for at least 3 years

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References

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

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