IG2 Hazards : Risk Assessment : Risk Handling

IG2 Hazards : Risk Assessment : Risk Handling

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  Part 2: RiskAssessment Organisation name: National Metal Company Date of assessment: January 11, 2025 Scope of risk assessment: Pattern Making Area, Moulding and Core Making Area, Furnace Section, Melting and Pouring Area, Cooling and Shakeout Area, Cleaning and Finishing Area, Heat Treatment Section, Casting section, Maintenance section, Machining Area, Quality Control and Testing Area, Storage and Dispatch Area. Hazard category and hazard Who might be harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title 1.Hazardous Substances Exposure to formaldehyde in concentration of 3 PPM and phenol concentrations of 5 PPM due to leakage in seal of resin mixing machine in core making section. Moulding Operator, Core Maker, Moulding Supervisor, Quality Control Inspector, Foundry Technician In the Core Making Section, workers were exposed to hazardous substances, specifically formaldehyde and phenol vapours, used in the production of resin-bonded sand cores. During routine operations, a resin Access was restricted to the Core Making Section during high-exposure tasks, limiting exposure to essential personnel only. Workers were provided with appropriate PPE, including chemical- resistant gloves, safety goggles and face shields. A. Switch to alternative core- making methods that do not involve chemicals such as shell-core method. 2-Months Section Head Process B. Replace the current resin with a safer, low-toxicity alternative using phenol free. 1-Month Section Head Process C. Installation of sensor for air quality monitoring should be carried out. 2-Week Section Head I/C D. Install localized exhaust ventilation systems near the resin mixing machine to capture and remove the chemical vapours. 3-Weeks Section Head Mechanical E. Use sealed systems and enhanced gaskets to 2-Weeks Section Head Mechanical
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  Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title mixing machine developed a leak in its seal, causing these chemicals to escape into the workspace. Air quality monitoring revealed formaldehyde concentrations of 3 ppm and phenol concentrations of 5 ppm, exceeding the permissible exposure limits of 0.75 ppm. It could result in irritation of the eyes, nose, and throat, along with headaches and dizziness. prevent leaks from the resin mixing machine. F. Train all personnel on the potential risks of formaldehyde and phenol exposure. 2-Weeks Site Trainer 2.Manual Handling Manual handling of heavy wooden patterns weighing around 40 kgs in pattern Labours, workers and daily wagers In the Pattern Making Section, workers were manually handling heavy wooden patterns, some weighing over 40 kgs. During a routine task, Paid Annual leaves were provided to the workers. Warning signage of manual handling hazard was installed. Anti-slip gloves were supplied to workers to improve grip during A. Replace heavy wooden patterns with lighter materials, such as aluminium and composite. 3-Months Section Head Mechanical B. Install overhead cranes in the Pattern Making Section to lift and transport patterns safely. 2-Months Section Head Mechanical C. Establish a strict weight limit policy requiring team 3-Weeks Lead Planning
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  Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title making section. workers attempted to lift a large pattern without assistance or mechanical aids. Mid- lift, the workers could experience severe back pain and drop the pattern while hitting their foot. It could result in musculoskeletal disorders (MSDs), chronic back pain and fatigue. handling tasks. lifting for patterns exceeding 20 kg. Officer D. Manual handling work permit should be implemented in the area. 2-Weeks HSE Officer E. Establish a job rotation schedule to limit repetitive manual handling tasks and reduce physical strain. 2-Weeks Lead Planning Officer F. Provide workers with training on proper manual handling techniques, emphasizing posture, balance, and load handling. 1-Month Site Trainer 3.Fire Molten metal spill along with oil residue near furnace in melting section due to spillage of molten metal from ladle crane fault. Furnace Operator, Melting Technician, Pouring Operator, Furnace Supervisor, Melting Supervisor In the Melting Section, a fire could broke out due to a molten metal spill combined with oil residue on the floor near the furnace. The spill occurred when a ladle crane Fire extinguishers were installed in the area. Fire alarms were installed in the area. Workers were provided with fire-resistant clothing (e.g., aluminized suits), heat-resistant gloves and safety boots and face shields for protection against molten metal splashes. A. Eliminate the use of combustible materials, such as wooden pallets, for temporary storage near the furnace area. 3-Months Section Head Mechanical B. Replace oil-based hydraulic systems in the ladle crane with fire- resistant hydraulic fluids to reduce the risk of ignition. 2-Months Section Head Mechanical C. Install a spill containment system, such as heat- resistant barriers, around the furnace to prevent 3-Months Section Head Mechanical
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  Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title malfunctioned, spilling molten metal near oil- soaked area. The oil could ignite, and the fire could quickly spread to nearby combustible materials, including wooden pallets used for temporary storage. Fire could result in skin blisters, pigmentation, skin burns etc. molten metal spills. D. Upgrade the ladle crane with fail-safe mechanisms and regular maintenance to prevent malfunctions. 2-Weeks Lead Planning Officer E. Establish a fire response plan, including evacuation procedures and emergency contact protocols. 1-Week Lead Planning Officer F. Train workers on the safe operation of melting equipment, proper maintenance, and emergency response procedures. 3-Weeks Site Trainer 4.Health, Welfare and Work Environment Soaring temperature reaching 45°C due to prolonged exposure to extreme radiant heat in melting Furnace Operator, Melting Technician, Pouring Operator, Furnace Supervisor, Melting Supervisor In the Melting Section, workers faced the specific hazard of prolonged exposure to extreme radiant heat exceeding 45°C emitted by uninsulated Sign boards were installed in the area indicating excessive temperatures in the area. For hydration, drinking water dispensers were installed in the area. Workers were provided with heat-resistant clothing, such as aluminized suits, to reflect radiant heat. A. Automate the pouring and furnace operations to reduce direct worker presence near the heat source. 1-Month Section Head Mechanical B. Install heat shields and reflective barriers around the furnace to redirect radiant heat. 2-Months Section Head Mechanical C. Insulate furnace surfaces with high-temperature- resistant materials to minimize heat radiation. 1-Month Section Head Mechanical
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  Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title section due to uninsulated furnace surfaces. furnace surfaces and molten metal. Poor ventilation in the area caused hot air to accumulate, further elevating the temperature. The absence of heat shields, localized cooling systems, and proper thermal insulation, left workers directly exposed to the heat. It could result in over sweating, heat stress, dehydration, heat stroke and fatigue. D. Upgrade ventilation systems to improve airflow and ensure hot air is promptly extracted from the area. 2-Weeks Section Head Mechanical E. Rotate workers to minimize individual exposure time to extreme heat conditions. 1-Month Lead Planning Officer F. Train workers on recognizing early symptoms of heat stress, dehydration, and fatigue. 2-Weeks Site Trainer 5.Noise Excessive noise exposure reaching 115 dB in casting section due to worn-out automated mould-shaking Casting Technician, Mold Maker, Pouring Operator, Casting Supervisor, Core Maker In the Casting Section, workers encountered a specific hazard of excessive noise Sign boards were installed in the area indicating excessive noise in the area. Workers were provided with noise-reducing earplugs or earmuffs rated for the specific noise levels A. Replace the worn out mould-shaking machine with a more efficient and quieter machine model. 3-Months Section Head Mechanical B. Substitute the current vibration dampers with advanced noise-reducing dampers. 1-Month Section Head Mechanical C. Install acoustic barriers around the mould-shaking 2-Months Section Head Mechanical
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  Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title machine. levels exceeding 115 dB, caused by a mechanical fault in one of the automated mould-shaking machines. The machine’s vibration dampers had worn out, leading to uneven operation and intensified noise emissions. Workers operating nearby could get noise-induced hearing loss, including temporary threshold shifts and tinnitus. of the work environment. machine and other noise- generating equipment. D. Upgrade the ventilation and exhaust systems with quieter models. 1-Months Section Head Mechanical E. Rotate workers to minimize their exposure time to high- noise areas. 1-Month Lead Planning Officer F. Train workers to identify signs of noise-induced hearing damage, such as tinnitus. 3-Weeks Site Trainer 6.Work, Equipment and machinery Unguarded rotating abrasive wheel rotating at high speed in finishing section lacking safety Surface Preparation Workers, Grinding and Polishing Technicians, Finishing Area Supervisors In the Finishing Section, workers were assigned to operate a high-speed metal Toolbox sessions were carried out in area on weekly basis. Warning signage of unguarded equipment was placed. Workers were supplied with cut-resistant gloves that are tight-fitting and less A. Replace the high-speed grinding machine with an automated grinding and polishing robot. 1-Month Section Head mechanical B. Use grinding machines with integrated safety features such as enclosed abrasive wheels. 2-Months Section Head Mechanical C. Install safety guards around the abrasive wheel to fully enclose moving 3-Months Section Head Mechanical
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  Hazard category and hazard Who mightbe harmed and how? What are you already doing? What further controls/actions are required? Timescales for further actions to be completed (within …) Responsible person’s job title guards. grinding machine used to smoothen casted components. Upon inspection, it was discovered that the machine lacked essential safety guards around the rotating abrasive wheel. This left the sharp, high- speed moving parts exposed during operation. During routine grinding, the worker's glove could get caught in the unguarded rotating wheel, pulling their hand toward the grinding surface. It could result in workers sustaining severe lacerations and bruises on their fingers. likely to get caught in rotating parts. parts while maintaining visibility. D. Add emergency stop buttons in accessible locations near the grinding machine to immediately halt operation. 2-Weeks Section Head I/C E. Establish strict standard operating procedures (SOPs) for using grinding machines. 1-Month HSE Officer F. Provide workers with thorough training on the safe operation of grinding machines. 1-Month Training In- charge