General Workshop Risk Assessment
General Risk AssessmentManagement Unit:School of EngineeringLocation: (Site/ Building/ Room)Mechanical Workshop Areas, Rms.201,301,Rankine BuildingAssessment Date:13/05/16Review Date:12/05/17Assessors Name:Denis KearnsJob Title:Workshop Unit ManagerTask / Activity: Carrying out a number of physical engineering tasks within the Mechanical Workshop areas such as drilling, fitting, welding,manual handling, guillotine, surface grinding, bandsaw, chop sawWhat are thehazards?(See list of samplehazards)Using generalmechanicalworkshopmachineryincluding lathes,mills, grinders,guillotines,welding plant,Band sawsWhat are the risks?abrasions, cuts, burns,eye injury, entanglement inmoving machinery,severance of limbs, crushinjuryWho might beharmed?(eg Staff, students,visitors)TechniciansRiskRatingRisk EvaluationWhat control measures are requiredto eliminate or reduce the risks? Appropriate PPE must be wornAccess to the workshopmachining areas are strictlyrestricted to authorisedpersonnel only.No one may operate workshopequipment unless they havereceived a sufficient trainingand permission from themanagement.Specific risk assessments formachinery and the generic riskassessment for power handtools have been completed andsafe systems of work issued tooperatives.Guards on the machines mustbe used.All workshop equipment isregularly maintained andserviced.Long hair must be completelycovered and suitable eyeprotection worn1Consequence(1 – 3)3Likelihood(1 – 3)1Overallrisk(C x L)3Low,Medium orHighM
Using powerhand tools andassociatedelectricalequipment foruse on machinetools.Electric shocks or burnsfrom using faulty electricalequipment with possibleelectric seizure or fatality.Abrasions and eye injury.Technicians,Logisticspersonnel Manual handlingof heavy/bulkyobjectsBack injury, crush injury,Entrapment, damage togoods being lifted ortransportedStaff, Students,Visitors Use ofHazardousSubstances such as solvents,coolants andirritating or hazardousvapours, skin sensitisation,dermatitis, burns,asphyxiationStaff, Students,visitors Weld curtains and anti-flashguards are used when deemedappropriateAppropriate PPE must be wornAccess to the workshopsportable electrical equipment isrestricted to certified personnelonly.There is a validated PATtesting for electrical safety oneach portable appliance.Electrical cables and plugsshould be regularly visuallyinspected by the user fordamage.Any defective equipment will bereported to the technician-incharge and taken out of use untilthe repair has been effected.Electrical equipment is alwaysoperated in accordance withmanufacturers' instructions.A risk assessment must becompleted for lifting heavy andbulky loads that present a risk ofinjury.Training in lifting techniques willbe provided for workshop staffwho undertake the lifting ofheavy loads.Appropriate PPE for liftingoperations must be worn.Appropriate lifting tackle usedfor specific job.Lifting equipment will beregistered with the University’sEngineeringInsurersandannual inspections carried out.Records of the inspections mustbe kept in the safety file.A COSHH risk assessment willcompleted for using substancesthat may present a hazard tohealth.A Material Safety Data Sheet(MSDS) must be kept together2313M313M212L
chemicals Slips and tripsStrains, bruising, limbbreakages, concussion,lacerationStaff, Students,Visitors FireBurns, asphyxiation, deathStaff, Students,Visitors with a risk assessment in theWorkshop Safety File for futurereference.All containers used for storageofhazardousandnonhazardous substances must besuitably labelled indicating theircontentsWorkshop working areas mustbe kept clear of obstructionsand the floor must be kept freefrom oil and swarf.Any spillages should becleaned up immediately.Any hazards such as trailingcables, defects to floorcoverings and faulty lightingetc. should be reportedimmediately to the technicianin-charge.All areas well lit.Equipment will be switched offwhen not in use for longperiods.All portable electricalequipment will be tested forelectrical safety at correctintervals and labelled with thedate of the test.Flammable substances must bekept away from naked flamesand ignition sources.Flammable substances arekept in an appropriate fireresistant metal cabinet.The fire alarm system isinstalled, maintained andtested.Workshop users must beacquainted with the FireRoutine Procedure for thebuilding.Fire Stewards are appointed tocover the workshop area.3212L313M
Working atheight(fall from astepladder)Strains, bruising, limbbreakages, concussion,lacerationsTechnicians,E&B Staff,Contractors Excessive Noise Damage tohearing.Staff, Students,Visitors Lone / Out ofHours (LOOH)Working Technicians,Students Non discovery ofinjured party whenseriously injured. Gas CylinderUsage andStorageCrush injury, Explosion ofgas, asphyxiationTechnicians,Students Users must be familiar with therisk assessment and safesystem of work for usingstepladders.Users must be familiar with theUniversity Guidance on the Useof Stepladders addersandstepladders/A stepladder will have a visualinspection by the user prior touse for damage.Stepladders are individuallyidentified and formalinspections is carried out andrecords of inspection kept.Any defective stepladder will beclearly labelled andimmediately taken out of use.If necessary the noise riskassessment should be carriedout and suitable hearingprotection supplied.Lone working in the workshopare strictly prohibited. A systemto avoid lone working may beallowed that requires an extraperson (buddy) to be presentduring certain machiningprocesses. Permission must begranted by management.Modern apprentice and nonexperienced personnel mustnot be left unsupervised inworkshop areas whilemachining work is in progress.Appropriate storage of gasbottle cylinders by use of rackor cradle system.Handing and moving cylinderswith correct bottle carrier.Equipment such as regulators,hosing, piping checked at4313M212L212L212L
regular intervals and replaced ifrequired.Required H&S knowledge andsafe working practice ofequipment being used.5
GUIDANCE ON COMPLETION OF RISK ASSESSMENT1. EXAMPLE HAZARDS THAT MAY BE APPLICABLE TO THE JOB or WORK ACTIVITYWorking at HeightNoiseHand toolsVibrationFalling objectsExtreme Heat / coldConfined spacesRepetitive hand/ arm movementSlippery/ uneven/ worn floorsRadiationPoor housekeeping / cleaningMachine operationObstructions/ projectionsLightingVehicle movementElectro MagnetManual handlingCompressed airFire / explosionPressurised systemsMechanical LiftingSubstances / materialsElectricityOther (specify on assessment)2. RISK MATRIX1 – Unlikely(injury rare, though possible)Likelihoodof harm2 – Possible(injury could occur occasionally)3 – Probable(injury likely to occur, can beexpected)Potential consequence of harm1 – Minor Injury2 – Significant Injury3 – Major Injury(e.g. hazard can cause illness, injury orequipment damage but the results would notbe expected to be serious)(e.g. hazard can result in serious injuryand/or illness, over 3 day absence)(e.g. hazard capable of causing deathor serious and life threatening injuries)1 – Low2 – Low3 – Medium2 – Low4 – Medium6 – High3 – Medium6 – High9 – Extreme3. RISK EVALUATIONThis is calculated by multiplying the likelihood against the consequence e.g. taking a likelihood of 1, which is classified as Unlikely and multiplying this againsta Potential Consequence of 2, which is classified as Significant Injury, would give you and overall Risk Rating of 2, which would result in an overall evaluationas a low risk.1 to 2 Low riskLow risks are largely acceptable, monitor periodically to determine situation changes which may affect the risk, or after significant changes3 to 4 Medium riskMedium risks should only be tolerated for the short-term and then only whilst further control measures to mitigate the risk are being planned andintroduced, within a defined time period.6 High riskHigh risks activities should cease immediately until further control measures to mitigate the risk are introduced. The continued effectiveness of controlmeasures must be monitored periodically.9 Extreme RiskWork should not be started or continued until the risk has been mitigated. Immediate action is required to reduce exposure. A detailed mitigation planmust be developed, implemented and monitored by senior management to reduce the risk before work is allowed to commence6
General Risk AssessmentManagement Unit:School of EngineeringLocation: (Site/ Building/ Room)Mechanical Workshop Areas, Rm201,301,Rankine bld.Assessment Date:24/02/16Review Date:24/02/17Assessors Name:Denis KearnsJob Title:Workshop Unit ManagerOperation of Workshop MillsTask / Activity:What are thehazards?(See list of samplehazards)Ejection of toolfromholder/spindleWhat are the risks? Eye injuryHead injury(concussion)Puncture woundWho might beharmed?(eg Staff, students,visitors) Operator/technician.Othertechnicians/labourers Ejection of jobfromtable/Mount Body injuries suchas crushing, bonebreakage RatingRisk EvaluationWhat control measures arerequired to eliminate or reducethe risks? 1Correct PPE must be wornat all times.Tooling must be securedbefore use with correctspeeds/feeds selected.Use coolant to prolong toollife, lubricate and preventoverheating of job.Worn tooling should bediscarded or sharpened.All safety guards must be inplace when machine is inoperation.Jobs/fixtures securelyfastened with correctclamping systems.Correct feeds and speedsselected.All safety guards must be inplace when machine is inoperation.Consequence(1 – 3)Likelihood(1 – 3)Overallrisk(C x L)Low,Medium orHigh313M313M
Machineentanglementwhile in motionfast traverse Body injuries suchas crushing, bonebreakagelacerations Operator/technician.Loose clothing/jewelleryshould be secured or notworn.Long hair tied back ornetted.Awareness of emergencystop buttonlocation/activation.Awareness of manualhandling obtained fromsafety course.Ask for assistance ifneeded.Use mechanical handlingdevices (forklift, hoists) forsafe handling.Never overstretch/reachwhen manoeuvring workpieces.All guards are in place andin good working order.All micro switches, limitswitches operational andwithout faults.313M313M212L Ear defenders to be wornwhen excessive noisegenerated.212L If dust is produced whileusing material such asmodelling foam, GRP,carbon fibre, a dust maskand extractor must be used.212L Disposable gloves should beworn if suffering from skinallergies or using irritantmaterial.212L Injury whenloading materialon/off machine. Back strain.Body injuries suchas crushing, bonebreakage.Injury to assistingpersonnel. Operator/technician.Othertechnicians/labourers Damagedmachine safetyequipment suchas guards, limit/micro safetyswitchesExcessive Noise Body injury tooperator.Injury to persons innear vicinity. Damage tohearing. Skincontaminationfrom coolant/oil Airborne DustParticlesOperator/technician.Respiratorydamage tooperator.Respiratorydamage to personsin the near vicinity.Skin/eye irritation. Skinirritation/damage. ents,staff bourersStudents,staff andvisitorsOperator.Labourer2
Spills and otherfloor hazards. Strains/bruising.Broken bones. ents,staff andvisitors Barrier creams are suppliedand should be used. Spills must be moped/wipedwhen occurrence noted.Any trip hazards such astrailing leads should beremoved immediately. 3212L
GUIDANCE ON COMPLETION OF RISK ASSESSMENT1. EXAMPLE HAZARDS THAT MAY BE APPLICABLE TO THE JOB or WORK ACTIVITYWorking at HeightNoiseHand toolsVibrationFalling objectsExtreme Heat / coldConfined spacesRepetitive hand/ arm movementSlippery/ uneven/ worn floorsRadiationPoor housekeeping / cleaningMachine operationObstructions/ projectionsLightingVehicle movementElectro MagnetManual handlingCompressed airFire / explosionPressurised systemsMechanical LiftingSubstances / materialsElectricityOther (specify on assessment)2. RISK MATRIX1 – Unlikely(injury rare, though possible)Likelihoodof harm2 – Possible(injury could occur occasionally)3 – Probable(injury likely to occur, can beexpected)Potential consequence of harm1 – Minor Injury2 – Significant Injury3 – Major Injury(e.g. hazard can cause illness, injury orequipment damage but the results would notbe expected to be serious)(e.g. hazard can result in serious injuryand/or illness, over 3 day absence)(e.g. hazard capable of causing deathor serious and life threatening injuries)1 – Low2 – Low3 – Medium2 – Low4 – Medium6 – High3 – Medium6 – High9 – Extreme3. RISK EVALUATIONThis is calculated by multiplying the likelihood against the consequence e.g. taking a likelihood of 1, which is classified as Unlikely and multiplying this againsta Potential Consequence of 2, which is classified as Significant Injury, would give you and overall Risk Rating of 2, which would result in an overall evaluationas a low risk.1 to 2 Low riskLow risks are largely acceptable, monitor periodically to determine situation changes which may affect the risk, or after significant changes3 to 4 Medium riskMedium risks should only be tolerated for the short-term and then only whilst further control measures to mitigate the risk are being planned andintroduced, within a defined time period.6 High riskHigh risks activities should cease immediately until further control measures to mitigate the risk are introduced. The continued effectiveness of controlmeasures must be monitored periodically.9 Extreme RiskWork should not be started or continued until the risk has been mitigated. Immediate action is required to reduce exposure. A detailed mitigation planmust be developed, implemented and monitored by senior management to reduce the risk before work is allowed to commence4
General Risk AssessmentManagement Unit:School of EngineeringLocation: (Site/ Building/ Room)James Watt Bld.Assessment Date:29/02/16Review Date:28/02/17Assessors Name:Denis KearnsJob Title:Workshop Unit MangerTask / Activity:What are thehazards?(See list of samplehazards)ENTANGLEMETWITH MOVINGPARTSOperating LathesWhat are the risks?LACERATION,ABRASION,BRUISING ANDBREAKING OFBONESWho might beharmed?(eg Staff, students,visitors)TECHNICIANOPERATORWhat control measures are requiredto eliminate or reduce the risks? EJECTION OFWORK PIECE,TOOLS, CHUCKKEY ANDSWARFLACERATION,ABRASION,BRUISING AND ,ACADEMICSRiskRatingRisk Evaluation Correct PPE (safety glasses,boots, overalls etc.) must beworn at all times.The chuck must be adequatelyguarded to prevent contactwhilst in motion.Operators must be made awarethat the lead screw or feedshaft rotate in use and may beunguarded with a danger ofclothing being drawn in when inuse.Materials should not projectbeyond the headstock gearingcover through the hollowspindle.The work-piece should be firmlyheld by a substantial amount ofmaterial in the chuck.Work mounted on a faceplateshould be securely bolted to itand counter balanced toprevent excessive vibration.Chuck keys should never beleft in the chuck and should be1Consequence(1 – 3)Likelihood(1 – 3)Overallrisk(C x L)Low,Medium orHigh313M313M
SWARF ANDOTHER WASTEMATERIALSLACERATION,BURNS AND EYEINJURYTECHNICIANOPERATOR SLIPPING ONSPILLAGES OFCUTTINGFLUIDS/SUDSALLERGIES ANDSKIN INFECTIONSFROM CONTACTWITH OIL;BRUISING ANDCUTSMANUALHANDLING OFCHUCKS ANDFACE PLATESBACK INJURY,TRAPPING OFHANDS, FINGERSAND FEETFINISHING INTHELATHEPOOR LIGHTINGAND FF LACERATION,ABRASION,BRUISING ANDBREAKING CADEMICS VARIOUS INJURIESMENTIONED ABOVETECHNICIANOPERATOR spring-loaded where possible toprevent this.Cutting tools must be securelyheld in the tool post andexcessive overhang of the toolshould be avoided to reducethe possibility of breakage.No attempt should ever bemade to remove swarf whilstthe machine is in motion, as itcan draw hands and clothinginto the machine.Swarf can also be extremelyhot and burns can occur.Suds oils that have beensprayed from the work-pieceonto the floor should be soakedup immediately with anabsorbent material and clearedaway.Chucks and face-plates can beexcessively heavy and mightrequire the assistance ofanother person or the use of ahoist to facilitate two personLifting .This hoist should alsoprevent the danger of chucksrolling off the bed onto thehands and feet of the operator.The use of files and abrasivessuch as emery cloth, to finishwork in the lathe is potentiallyhazardous and should not beencouraged. Be alert at alltimes with no distractions ifhaving to use this method.Work pieces should alwayshave good local lighting fromthe lathe and area workshoplighting to allow for safe work.2212L212L313M313M212L
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GUIDANCE ON COMPLETION OF RISK ASSESSMENT1. EXAMPLE HAZARDS THAT MAY BE APPLICABLE TO THE JOB or WORK ACTIVITYWorking at HeightNoiseHand toolsVibrationFalling objectsExtreme Heat / coldConfined spacesRepetitive hand/ arm movementSlippery/ uneven/ worn floorsRadiationPoor housekeeping / cleaningMachine operationObstructions/ projectionsLightingVehicle movementElectro MagnetManual handlingCompressed airFire / explosionPressurised systemsMechanical LiftingSubstances / materialsElectricityOther (specify on assessment)2. RISK MATRIX1 – Unlikely(injury rare, though possible)Likelihoodof harm2 – Possible(injury could occur occasionally)3 – Probable(injury likely to occur, can beexpected)Potential consequence of harm1 – Minor Injury2 – Significant Injury3 – Major Injury(e.g. hazard can cause illness, injury orequipment damage but the results would notbe expected to be serious)(e.g. hazard can result in serious injuryand/or illness, over 3 day absence)(e.g. hazard capable of causing deathor serious and life threatening injuries)1 – Low2 – Low3 – Medium2 – Low4 – Medium6 – High3 – Medium6 – High9 – Extreme3. RISK EVALUATIONThis is calculated by multiplying the likelihood against the consequence e.g. taking a likelihood of 1, which is classified as Unlikely and multiplying this againsta Potential Consequence of 2, which is classified as Significant Injury, would give you and overall Risk Rating of 2, which would result in an overall evaluationas a low risk.1 to 2 Low riskLow risks are largely acceptable, monitor periodically to determine situation changes which may affect the risk, or after significant changes3 to 4 Medium riskMedium risks should only be tolerated for the short-term and then only whilst further control measures to mitigate the risk are being planned andintroduced, within a defined time period.6 High riskHigh risks activities should cease immediately until further control measures to mitigate the risk are introduced. The continued effectiveness of controlmeasures must be monitored periodically.9 Extreme RiskWork should not be started or continued until the risk has been mitigated. Immediate action is required to reduce exposure. A detailed mitigation planmust be developed, implemented and monitored by senior management to reduce the risk before work is allowed to commence4
General Risk AssessmentManagement Unit:School of EngineeringLocation: (Site/ Building/ Room)Assessment Date:Assessors Name:Review Date:Denis Kearns(See list of samplehazards)Eye InjuriesWheel ExplosionJob Title:Workshop Unit ManagerOperation of Surface GrinderTask / Activity:What are thehazards?Rm 256 (level 2)What are the risks?High speed particlesinjuring eyeShattered stone wheelcausing body injuryWho might beharmed?(eg Staff, students,visitors)Technical Staff,Logistic Staff,Maintenancepersonnel“RiskRatingRisk EvaluationWhat control measures are requiredto eliminate or reduce the risks? Machine guar
General Risk Assessment 1 Management Unit: School of Engineering Location: (Site/ Building/ Room) M
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