NEBOSH

MANAGEMENT OF HEALTH AND SAFETY

UNIT IG1:
For: NEBOSH International General Certificate in Occupational Health and Safety

Open Book Examination

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Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

Task 1: Audit approach

1 (a)
The positive aspects of the approach taken to the audit of the production department,
based on the scenario

1.Independent Auditing Team - The audit was performed by a different department's

internal auditor from a different department (Worker A) to maintain objectivity and limit
bias.

2. Adhered to the Well-established Audit Procedures – The Health Safety Manager

confirmed that the audit complied with the written procedure of that organisation, thus
sustaining the uniformity and credibility of the audit.

3. Reporting of Data – Initially, the Health Safety Manager reached out by email to the
Production Manager (PM) and then followed up face to face when a response was not
forthcoming, which is aptly identified as persistence and commitment.

4. The audit included complete examination of essential production stages such as raw
material stores along with mixing operations quality checks and finished product
distribution in order to offer a complete assessment.

5. Completing on-site observations allowed staff to conduct actual site inspections for
assessing operational settings and equipment state and safety routines directly.

6. The auditors obtained informational insights about safety problems and employee
circumstances and reported difficulties by communicating directly with Supervisor B and
Worker C.

7. The audit emphasized both correct PPE usage as an acceptable practice and
deficiencies for safety improvement because it wanted to motivate workers to follow
proper procedures.

8. The audit exposed key safety problems because it revealed the presence of outdated
risk assessments as well as the lack of maintenance records combined with chemical
spillages and poor housekeeping and difficulties accessing documentation. These
discoveries helped identify fundamental safety issues.

9. Auditors examined protective equipment policies while asking for official safety
documentation that contained risk assessment records along with maintenance logs and
accident reports to maintain proper documentation standards.

10. A structured system of classifying audit findings separated them into Good Practice
(GP) areas alongside Opportunities for Improvement (OFI) along with their own category
for Non-Compliance (NC) elements which simplified decision

These positive aspects ensured a thorough, structured, and impactful audit that led to
significant health and safety improvements in the production department.

Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

1 (b)
Reviewing findings from audits is crucial for continuous improvement and ensuring a safe
and compliant work environment. Here are eight key reasons why reviewing audit
findings is important

1. Auditing findings enable organizations to find and fix non-compliance issues which
reduces their legal exposure while minimizing financial risks.

2. Workplace safety receives improvement when hazards and risks become apparent
through audits which trigger corrective measures to avoid workplace incidents and health
problems.

3. Systematic assessment of audit outcomes reveals emerging patterns together with

deficiencies that need improvement to develop safety-enhancing organizational practices.

4. Professional assignments help responsible personnel meet prescribed change

implementation deadlines.

5. Operational efficiency strengthens through the examination of non-optimal processes

alongside poor housekeeping practices which produce better productivity coupled with
decreased downtime periods.

6. The implementation of audit findings creates an engaging workplace environment

because employees believe that their safety concerns have been validated leading to better
compliance outcomes.

7. Use of audit findings strengthens support for process improvement initiatives because
they backed up the successful bulk storage implementation in the presented scenario.

8. Health and safety regulatory compliance and reputation management improvement

occur through identifying and acting on audit results to preserve organizational standing
and prevent regulatory penalties.

By reviewing audit findings, organisations can create a safer, more efficient, and legally
compliant workplace while fostering a culture of continuous improvement.

Task 2: Change management controls

2
During the project to implement bulk delivery, storage, and transfer of raw materials,
several changes could have required management of change controls to ensure health
and safety risks were properly assessed and mitigated.

1. Introduction of Bulk Storage Tanks A change occurred through the establishment of

new storage tanks dedicated to raw materials. New safety assessments and emergency
procedures for spill management and tank ruptures must be developed because of
potential tank leaks and pressure build up and material overflow situations.

2. Changes in Raw Material Delivery Method A shift occurred which transformed 25-litre
drum handling into tanker deliveries. The new method of raw material handling through

Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

 tanker unloading creates three important risks that need proper updates to existing safe
operating procedures (SOPs).

3. Installation of Pipework for Material Transfer The implementation of change involved

tank-to-mixer chemical transfer through new pipework systems. The installation of the
pipe system leads to three main consequences: operators need to inspect it regularly and
create preventive maintenance plans while also installing leak detection equipment.

4. Changes in Manual Handling Requirements Manual worker tasks of transporting 25-

litre drums by stairs to mixers have been eliminated. The change reduces worker manual
handling risks yet demands employee instruction for new transfer practices and fresh
ergonomic assessment protocols.

5. Elimination of Chemical Drums in Production Area The production area will no longer
see the build-up of chemical drums which remain either full-empty-partially full throughout
the area. This safety improvement has bettered workplace cleanliness and reduced spill
hazard while requiring analysis to determine how to minimize mixing errors among bulk
storage chemicals.

6. Increased Production Speed and Capacity The manufacturing duration for each batch
decreased from two hours until it reached the one-hour limit. Higher process speeds will
result in worker exhaustion whereas equipment deterioration requires organizations to
review operational schedules and maintenance protocols and production monitoring
systems.

7.Modifications to Emergency Procedures Different chemical storage and transfer

operations form a part of this change. The modification requires organizations to develop
modernized emergency response protocols featuring updated fire protection guidelines
as well as chemical leakage control measures together with evacuation safety
procedures.

8.The organization requires training along with competency assessments to meet the
needs. Workers will need to operate new systems and execute different procedures as
part of their responsibilities. The organization needs training sessions combined with
competency checks to verify worker comprehension of both safety processes and
equipment operating methods.

Task 3: Training to develop competence

3
Department require targeted training to ensure they can operate safely and efficiently
within the new system
1. New safety protocols for maintaining chemical bulk storage tanks and performing
transfers are essential for all staff members to learn. The team of workers need to learn
about secure practices when receiving, storing and moving chemicals between bulk
storage tanks and mixers. Unfortunately manual handling of the 25-liter drums has been
discontinued so workers need to prevent new risks that arise from bulk mixing and
storage valve errors as well as leakages.
2. Safe Operation of the Bulk Storage System The new storage tanks, piping systems
along with pumps require workers to acquire knowledge for operational and monitoring
functions in a safe manner. The new pipeline system represents failure points where
corrosion along with leaks and overflows can occur.

Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

 3. Emergency Spill Response Training The effective response of workers to chemical
spills will reduce health along with safety and environmental risks. The past chemical spill
incidents combined with slip-related injuries which required a need for adequate spill
response training.
4. Personal Protective Equipment (PPE) Usage and Maintenance Workers need to learn
how PPE should be worn properly while also learning its boundaries for use and
preserving its condition. The review of PPE comfort and selection practices became
necessary to protect workers' health after Worker C developed dermatitis despite proper
PPE implementation being marked as a Good Practice during the audit.
5. Manual Handling Risk Awareness and Prevention Although bulk storage decreased
lifting duties workers need to receive instruction about proper ergonomic techniques for
remaining manual operations. The previous injury to a worker's back occurred while he
lifted drums at the workplace. Some remaining tasks continue to need lifting awareness
even though handling tasks have decreased.
6. Equipment Maintenance and Inspection Training Workforce members need to identify
equipment deterioration signs throughout mixers, pumps and pipelines which enables
them to report problems before equipment breakdowns occur. Corrosion was found on
the motor along with seal wear while maintenance logs were absent for a period of six
months.
7. Fire and Explosion Hazard Awareness Employees need to understand the fire hazards
connected to chemicals in addition to proper chemical storage and handling together with
emergency response procedures. Implementing bulk storage solutions demands extra
fire prevention strategies and worker training because bulk storage heightens fire risk
factors.

8. The Maintenance and Repairs operations require a Permit-to-Work (PTW) System for
proper control measures. Workers performing maintenance on tanks pipes and mixers
need a proper understanding of the PTW procedures to avoid chemical exposures. The
former maintenance system proved deficient thus resulting in hazardous equipment
conditions due to corrosion.

9. Workers should complete Confined Space Entry Awareness training if it applies to their
duties. Staff members performing storage tank or restricted space maintenance and
cleaning duties must have complete knowledge of entry permit protocols as well as
atmospheric evaluation and rescue emergency systems. Vehicles and large containers
that serve as bulk storage produce new confined areas that were not present when the
company used drums for holding materials.

10. Regulatory Compliance and Chemical Safety Awareness Industrial employees need
to recognize the requirements that exist for storing chemicals and handling materials
while protecting environmental zones. The inspection discovered that expired documents
existed together with a history of unreported workplace accidents thus demonstrating the
importance of following regulatory protocols.

11. Worker Well-being and Fatigue Management Higher production speeds are enabled
through the new system though worker fatigue requirements and safety regulations need
to be tracked for sustainable safety and productivity levels. Worker C reported tiredness
combined with insufficient housekeeping because the company needs to manage
workloads properly and prevent employee fatigue-induced incidents.

Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

Task 4: Procedural controls

4
The procedural controls could be in place to reduce the likelihood of an incident when
handling chemicals on site that establish safe working practices, compliance, and
risk mitigation.

1. Standard Operating Procedures (SOPs) for Chemical Handling

Standard Operating Procedures establish a system of continuous safe methods that
workers must follow when they handle chemicals during receipt transfer and use
operations. Staff operated their chemical processes manually until the current system
change. The original approach produced spills with worker injuries while causing
dermatitis among personnel. The newly established bulk system requires updated
procedures for its successful implementation.

2. Chemical Spill Prevention and Clean up Procedure

Workers follow clear instructions for both spill prevention and correct leak clean up
procedures to decrease exposure dangers and lower the chance of slipping accidents.
During the audit inspection the team discovered spillage of chemicals which resulted in a
worker sustaining an injury following their slide down the mixer stairs.

3. The area where hazardous work takes place requires authorization through the Permit-
to-Work (PTW) System. Before starting high-risk maintenance operations on storage
tanks along with mixers workers need to gain official approval through the authorization
process. Worn mixer seals combined with signs of corrosion occurred because
maintenance activities were not documented for a six-month period which heightened
possible equipment failures.

4. Safe Chemical Storage and Segregation Policy The proper storage and safe
containment of chemicals according to policy protects against chemical contamination
and accidental reactions along with leaks. Accumulated chemical drums created exit
hindrances while poor storage protocols resulted in product waste at the affected site.

5. PPE Usage and Maintenance Procedure Each worker must wear designated PPE
properly and understand its correct replacement and upkeep schedule. The Good
Practice of proper PPE usage led to dermatitis in Worker C which revealed the need to
assess both glove quality and employee use practices.

6. Regular Inspection and Preventative Maintenance Procedure The maintenance

procedure ensures safe operational status for mixers alongside storage tanks and
pipework and pumps therefore preventing equipment breakdowns and chemical leaks.
No one had updated the mixer maintenance log since the previous six months which
resulted in corroded equipment and damaged seals that raised the possibility of
equipment failures.

7. Emergency Response and First Aid Procedure The emergency procedure

demonstrates to workers what actions they need to take to handle chemical exposure
and spills while indicating the exact location of first-aid kits. The first-aid kit required
additional effort to access since its location was on top of a filing cabinet.

8. Incident Reporting and Investigation Procedure

The procedure requires employees to alert authorities about workplace accidents and
close calls then uses investigations for ongoing safety enhancement. The audit revealed
workers who suffered from a fall down mixer stairs incident failed to receive investigation
or notification to the regulatory authority thus failing to generate preventative measures
for future incidents.

Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

Task 5: Financial arguments to improve health and safety

Task 6: Obligations of employers to workers

6
1. Recommendation 10(a) – Safe Working Environment Employers need to guarantee
that workplaces together with machinery equipment and processes remain risk-free from
both hazards to health and physical safety. How This Was Not Followed:

1. Mixer Equipment in Poor Condition The mixer motor deteriorated through corrosion
combined with worn seals which created an increased chance of chemical leakage
and malfunction of machinery. The absence of recorded maintenance during the
previous half year period broke down preventive safety regulations.

2. Chemical Spills and Poor Housekeeping The presence of chemicals scattered

across the flooring generated exposure hazards and risk of slipping accidents. A
worker burnt themselves after slipping on spilled chemicals near the stairs leading to
falling down which required hospitalization and an absence of three weeks.

3. Blocked Emergency Exit Two chemical drums positioned in front of the emergency
exit disturbed both safety and evacuation procedures.

2. Recommendation 10(b) – Safe Handling of Substances Staff must verify that chemical,
physical, biological substances remain hazard-free as long as safety protocols remain
operational. How This Was Not Followed:

4. Unsafe Chemical Storage Drums that contained full liquid supplement and partial
and empty bottles were stacked randomly near mixers leading to possible
contamination and spillage and fire-related hazards.

5. Improper Manual Handling of Chemicals During the inspection the employee

engaged in carrying 25-litre heavy drums upwards causing their back to sustain
damage. A labourer suffered from a back injury because he carried these drums
although he was already on medical leave for his injured back.

6. Dermatitis from Chemical Exposure The repeated skin contact of Worker C with
chemicals that leaked caused dermatitis to develop. The plant failed to implement any
solutions after one of their workers informed the production manager about the
problem.

3. Recommendation 10(c) – Risk Assessments and Safety Measures Employers need to

both assess workplace risks and create safety protection systems which reduce exposure
to workplace dangers. How This Was Not Followed:

7. Risk Assessments Were Outdated Three years passed since the previous risk
assessment became obsolete due to neglected new workplace hazards as well as
equipment deterioration and altered manufacturing operations.

8. Lack of Accident Investigation and Reporting The organization missed the chance
to stop recurring incidents when they failed to assess the serious worker fall that
occurred because of a chemical spill. The regulator was neither informed nor

Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

 contacted about the incident which violated legal reporting duties.

9. No Document Control for Safety Records Health and safety documents became
difficult to access so important safety protocols remained inconsistent throughout
production processes.

4.Recommendation 10(d) – Training and Supervision Organizations are responsible for

providing detailed instructions together with proper supervision to protect their employees
from harm. How This Was Not Followed:

10. Lack of Worker Training on Safe Chemical Handling The safety protocols were
violated by Worker C when they discarded their gloves in a situation that presented a
chemical danger. Such behaviour suggests workers did not get appropriate education
regarding PPE use alongside hazardous substance management.

11. Supervisors Were Not Informed of the Audit A scheduled audit remained
unknown to supervisors because the production manager failed to communicate
properly and display active supervisory oversight.

12. No Structured Training on New Bulk Storage System No procedures existed to

instruct workers about the new bulk storage tanks after the company moved from 25-
litre drums.

5.Recommendation 10(e) – Personal Protective Equipment (PPE) Employers must

provide without charge the proper protective equipment that also must be correctly used
by workers along with proper equipment maintenance protocols. How This Was Not
Followed:

13. Personal protective equipment did not provide enough defence against chemical
hazards during work activities. The identified Good Practice (GP) of PPE use during
audits did not protect Worker C from chemical exposure because PPE was either
insufficient or managed improperly.

14. The PPE provided to workers caused problems which affected their comfort level.
Workers experienced discomfort with their gloves which caused them to improperly
take off the gloves when working with chemicals. The organization provided no
alternative PPE options to enhance worker compliance with safety protocols.

6.Recommendation 10(g) – Workplace Welfare and Hygiene Employees need access to

complete welfare features including first aid facilities and clean hygiene measures from
their employers. How This Was Not Followed:

15. Inaccessible First-Aid Kit In an emergency situation it would be hard to reach the
first-aid kit which was located on top of a filing cabinet.

Task 7: Indicators of health and safety culture

Task 8: Good practice within a health and safety management system

Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025

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Answer sheet IG1-0047-ENG-OBE-V1 Feb25 © NEBOSH 2025