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Risk Register

Risk
Register #

0001

Risk Area/Process

Activity

Identified Risk Scenario

Assessment, deployment,
Office of the General implementation, review,
failure to conduct effective strategic
Manager
and adjustment phase of business plan
SBPP

FM-RSK004
Rev. 00

Severity

Overall Risk
Likelihood

Risk Level

business loss

HIGH

ECAOGM001

Establish procedure for


regular conduct of
reviews and deployment
meetings

OGM

Impact

Reference

Prevention/Mitigation
Action(s)

Person-in-charge

0002

Budgeting

Review of business
performance

Unavailable data

-delay in business performance


review
-delay in setting goals and
targets

MEDIUM

ECAOGM002

-double time in preparing


the budget
-rescheduling of the
activity

OGM

0003

Budgeting

Setting goals and targets

Setting of unrealistic goals and targets

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

0004

Budgeting

Dissemination of goals
and target

misinterpretation of goals and targets

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

0005

Budgeting

Formulation of action
plans and budget

miscalculation

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

0006

Budgeting

Review of action plans and


misinterpretation/miscalculation
budget

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

0007

Budgeting

Review of action plans and


delay in reviewing budget drafts
budget

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

0008

Budgeting

Revision of budget drafts

miscalculation

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

Budgeting

Review of budget drafts


and preparation of master miscalculation
budget

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

0010

Budgeting

Presentation to President
for approval

delay in performing projected


activity

HIGH

ECAOGM003

review action plans and


variances

OGM

0011

Budgeting

Revision of master budget


discrepancy in budget figures
draft

misappropriation of resources

HIGH

ECAOGM003

review action plans and


variances

OGM

0012

Budgeting

Monitoring performance

inaccurate data

business loss

HIGH

ECAOGM003

review action plans and


variances

OGM

0013

Budgeting

Conducting
corrective/preventive
action

inappropriate analysis

recurrence of problem/business
loss

HIGH

ECAOGM003

review action plans and


variances

OGM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0009

disapproval

0014

Identification of
Hazard/Aspect
occupational health and
Identification and Risk safety
Assessment
hazards/environmental
aspects per activity

failure to indentify certain hazard/impact

occurrence of incident

MEDIUM

0015

Identification of
Hazard/Aspect
occupational health and
Identification and Risk safety
Assessment
hazards/environmental
aspects per activity

section/department representative not


available

delay in conducting the


assessment

MEDIUM

Choose group of
skilled/trained assessor in
ECA-EHS004 conducting assessment
for brainstorming

IMR

Contingency Action(s)

Source for back-up resource


persons to conduct analysis

Person-in-charge

IMR

0016

Hazard/Aspect
Identification of associated
Identification and Risk hazards for health, safety failure to identify a certain hazard/impact
Assessment
and environmental

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0017

Hazard/Aspect
Identification and Risk Formulation of controls
Assessment

delay in implementation of
needed program

MEDIUM

ECA-EHS005

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0018

Hazard/Aspect
Finalization of assessment
Identification and Risk
late finalization of reports
reports
Assessment

delay in implementation of
needed program

MEDIUM

ECA-EHS005

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0019

Hazard/Aspect
Implementation of
Identification and Risk approved programs/action failure to implement the programs
Assessment
plans

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0020

Hazard/Aspect
Review of risk assessment
failure to make controls analysis
Identification and Risk
and controls
Assessment

delay in implementation of
needed program

MEDIUM

ECA-EHS005

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

MEDIUM

-Regular updating of
company and other
requirement register thru
websites/visit to
government libraries
ECA-EHS002 -Include JIS requirements
in the work instructions
posted in the work area.
-Establish procedure for
handling customer
complaints.

IMR

MEDIUM

-Regular updating of
company and other
requirement register thru
websites/visit to
government libraries
ECA-EHS002 -Include JIS requirements
in the work instructions
posted in the work area.
-Establish procedure for
handling customer
complaints.

IMR

MEDIUM

-Group of skilled/trained
assessor is used in
conducting the
assessment for
ECA-EHS004 brainstorming
-competence of SO/PCO
on updating the register
-Competence of SO/PCO
in evaluating reports

IMR

0021

Identification and
Compliance to
Applicable Legal &
other requirements

0022

Identification and
Compliance to
Applicable Legal &
other requirements

0023

Identification and
Compliance to
Applicable Legal &
other requirements

failure to make controls analysis

Receipt and review of new


laws, regulations, and
regulatory infractions/customer
failure to have the update of requirements.
code of practice, and other
complaints
requirements

Verification of applicability

Wrong judgment if the requirement is


applicable or not.

Update of legal and other


Unavailability of SO/PCO
requirement register

regulatory infractions/customer
complaints

delay in updating the register.

Source for back-up resource


persons to conduct analysis

0024

Internal/External
Communication

0025

Internal/External
Communication

0026

Internal/External
Communication

Communication roll out

fail to communicate information

Processing of CA's and


PA's and then conducting failure to prepare the necessary CA/PA
risk Assessment

Circulation of resolutions
(CA's and PA's)

failure to circulate the resolutions

violation to any requirements

MEDIUM

-Regular updating of
company and other
requirement register thru
websites/visit to
government libraries
ECA-EHS002 -Include JIS requirements
in the work instructions
posted in the work area.
-Establish procedure for
handling customer
complaints.

IMR

IMR

recurrence of problem or
infractions to requirements

MEDIUM

-Regular updating of
company and other
requirement register thru
websites/visit to
government libraries
ECA-EHS002 -Include JIS requirements
in the work instructions
posted in the work area.
-Establish procedure for
handling customer
complaints.

pending of the matter that


needs closure

MEDIUM

ECA-EHS003

IMR

-Maximize processing
time for handling
customer
-coordinate with the
requesting party for the
reasons of delay

IMR

recurrence of problem or
infractions to requirements

MEDIUM

-Regular updating of
company and other
requirement register thru
websites/visit to
government libraries
ECA-EHS002 -Include JIS requirements
in the work instructions
posted in the work area.
-Establish procedure for
handling customer
complaints.

Emergency
Preparedness and
Control

Review of risk assessment


needed actions may not be
failure to review the risk assessment results
result
implemented

MEDIUM

ECA-EHS005

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0029

Emergency
Preparedness and
Control

Identification of
failure to identify some hazards/aspects of
hazards/aspect that would
the activity
lead to an emergency.

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0030

Emergency
Preparedness and
Control

Development/review of
emergency procedures

failure to develop emergency procedures

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0031

Emergency
Preparedness and
Control

Implementation of
procedure/conducting
trainings

failure to implement the established


procedures

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0032

Operational control

Review of the risk


assessment result

failure to review the risk assessment results occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0027

Internal/External
Communication

0028

Implementation of CA's
and PA's

failure to include the necessary CA/PA

0033

Operational control

Identification of medium
and high risk
aspects/hazards that
would require procedural
control

failure to identify some hazards/aspects of


the activity

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0034

Operational control

Development of
procedures then
(4)conducting risk
assessment

failure to consider the identified


hazard/aspects

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0035

Operational control

Implementation of
procedure

failure to implement the established


procedures

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0036

Operational control

Training of concerned
personnel

failure to give the training needed

occurrence of incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

0037

Operational control

Monitoring for compliance


failure to monitor procedure effectiveness
effectiveness

necessary corrective action will


not be implemented

MEDIUM

ECA-EHS005

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

necessary emergency
responses may not be done

MEDIUM

ECA-EHS006

Established company
rules and regulations of
incident/accident
reporting

IMR

IMR

0038

Informing
failure to inform the concerned
Incident Investigation supervisor/company nurse
supervisor/company nurse
of any incident that occurs

worsening of the victim's


situation

MEDIUM

-Choose group of
skilled/trained assessor in
conducting assessment
ECAfor brainstorming
EHS001, -Availability of company
ECA-EHS007 clinic, nurse and trained
first aiders
-Employees are provided
with health card

Evaluation of accident
report then review of
failure to evaluate accident report
existing HAIRA, EPC, & ERI

recurrence of the incident

MEDIUM

ECA-EHS001

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

Implementation and
monitoring approved
recommendation and
conducting verification

failure to monitor corrective/preventive


actions

necessary corrective actions


may not be implemented and
effective

MEDIUM

ECA-EHS005

Choose group of
skilled/trained assessor in
conducting assessment
for brainstorming

IMR

Installation of new
New Infrastructure/
equipment and/or
Equipment Installation
infrastructure

Lack of safeguards installed over moving


parts of machines installed

major injury

MEDIUM

-Availability of company
clinic, nurse and trained
ECA-EHS007 first aiders
-Employees are provided
with health card

PCO/SO/ IMR

0043

Records management Filing of records

failure to keep important record

no evidence to present during


audits

MEDIUM

Established procedure for


ECA-QAD001 corrective/preventive
action

IMR/DCC

0044

Records management

MEDIUM

ECA-QAD001

0039

Incident Investigation

Sending victim to
treatment

0040

Incident Investigation

0041

Incident Investigation

0042

Monitoring of active and


archive files

delayed treatment

Fire hazard, unauthorized person enters the


loss of files,/record
records center

Availability of fire
extinguisher in the area

IMR/DCC

0045

Handling Customer
Complaints

Receipt and evaluation of


Lack of information about the complaint
complaint

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0046

Handling Customer
Complaints

Conducting
corrective/preventive
action

Insufficient root cause analysis

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0047

Handling Customer
Complaints

Informing the customer

failure to inform customer about the


corrective/preventive action

delay closing of complaint

MEDIUM

ECA-QAD003

Established procedure for


different QA activities

IMR

0048

Internal IMS Audit

Actual audit

failure to identify strengths and areas for


improvement

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0049

Internal IMS Audit

Actual audit

Exposure to hazards on different area


scheduled for audit

injury

MEDIUM

ECA-QAD004

-Establishment of First
Aid Team
-Availability of company
clinic and nurse

IMR

0050

Process Monitoring
and Measurement

no evidence to present during


audits

MEDIUM

ECA-QAD001

Availability of fire
extinguisher in the area

IMR

0051

Process Monitoring
and Measurement

Submission of report to
IMR

late submission of report

delayed conduct of reviews

MEDIUM

ECA-QAD003

Established procedure for


different QA activities

IMR

0052

Analysis of Data

Receipt of reports from


various
sections/departments

fail to collect reports

delayed analysis

MEDIUM

ECA-QAD003

Established procedure for


different QA activities

IMR

0053

Analysis of Data

Forwarding statistical
report to concerned
Division Manager

Late submission of statistical report

delayed implementation of
action plan

MEDIUM

ECA-QAD003

Established procedure for


different QA activities

IMR

Failure to identify potential/existing


nonconformity

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

Preparation of reports
supporting performance Lacking details on support documents
indicators

0054

Identification of
Corrective/ Preventive
potential/existing
Action
nonconformity

0055

Verification and analysis of


Corrective/ Preventive
poor verification & analysis of
potential/existing
Action
nonconformity
nonconformity

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0056

Determining the cause of


Corrective/ Preventive
potential/existing
Action
nonconformity

poor root cause analysis

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0057

Solution formulation and


Corrective/ Preventive
update/conduct of risk
Action
assessment

formulation of ineffective action plans

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0058

Corrective/ Preventive Implementation of


Action
approved action plans

Late implementation of action plans

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0059

Review and recording of


Corrective/ Preventive actions taken and
Action
standardization of
implemented action

failure to review the effectiveness of action occurrence/recurrence of


plans
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0060

Corrective/ Preventive Closing out of the


Action
nonconformity

Failure to close out the nonconformity

occurrence/recurrence of
potential/existing problems

MEDIUM

Established procedure on
ECA-QAD002 corrective/preventive
action

IMR

0061

Software and
Backing up all data (files
Hardware Maintenance and programs)

Failure to check files and program backup

loss of records and program

MEDIUM

ECA-QAD005

Retrieve data, program


for backup

IT Personnel

0062

Software and
Backing up all data (files
Hardware Maintenance and programs)

External hard drive is not in good working


condition

loss of records and program

MEDIUM

ECA-QAD005

Retrieve data, program


for backup

IT Personnel

0063

Software and
Quarantine of infected
Hardware Maintenance files

Failure to quarantine infected files

loss of data and program

MEDIUM

ECA-QAD005

Retrieve data, program


for backup

IT Personnel

0064

Software and
Cleaning/healing of
Hardware Maintenance infected files

Failure to clean infected files

loss of data and program

MEDIUM

ECA-QAD005

Retrieve data, program


for backup

IT Personnel

0065

Software and
Copying clean file(s) to
Hardware Maintenance recent backup

Failure to copy files to recent backup

loss of data and program

MEDIUM

ECA-QAD005

Retrieve data, program


for backup

IT Personnel

0066

Software and
Copying clean file(s) to
Hardware Maintenance recent backup

Failure to copy files to recent backup

loss of update data to backup


drive

MEDIUM

ECA-QAD005

Retrieve data, program


for backup

IT Personnel

0067

Software and
Conducting preventive
Hardware Maintenance maintenance

exposure to radiation

ill health

MEDIUM

ECA-QAD006

0068

Customer Satisfaction Conducting customer


Determination
survey

Exposure to computer radiation

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

0069

Customer Satisfaction Gather the issued


Determination
customer survey

Incomplete number of survey results

incomplete analysis report for


number of customers

MEDIUM

ECA-SAM008

Revise procedure to
account for monitoring
follow-up and timeliness
of sending of the survey.

Account
Executive, Sales
and Marketing
Manager

0070

Customer Satisfaction Gather the issued


Determination
customer survey

Exposure to computer radiation

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

IT Personnel

0071

Inquiry and Order


Handling

Preparation and
submission of quotation
and drawing

Inaccurate product specification & drawing wrong order/product


vs. customer requirement
specifications

MEDIUM

ECA-SAM007

Forms are being used to


ensure all requirements
are properly translated
and documented

Account
Executive, Sales
and Marketing
Manager

0072

Inquiry and Order


Handling

Preparation and
submission of quotation
and drawing

Exposure to computer radiation

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

0073

Inquiry and Order


Handling (Local)

Preparation and signing of


Exposure to computer radiation
job order

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

MEDIUM

-Thorough coordination
with the customers for
the issuance of job orders
Account
or purchase orders on
Executive, Sales
ECA-SAM001
time.
and Marketing
Established procedure for
Manager
handling customer
complaints

MEDIUM

-Thorough coordination
with the customers for
the issuance of job orders
Account
or purchase orders on
Executive, Sales
ECA-SAM001
time.
and Marketing
Established procedure for
Manager
handling customer
complaints

MEDIUM

-Thorough coordination
with the customers for
the issuance of job orders
Account
or purchase orders on
Executive, Sales
ECA-SAM001
time.
and Marketing
Established procedure for
Manager
handling customer
complaints

0074

0075

0076

Order Handling
(Export)

Order Handling
(Export)

Order Handling
(Export)

Receipt of Job Order

Receipt of Job Order

Receipt of Job Order

Unable to receive job order

Loss of Job Order

Late receipt of job orders

Delay of delivery to the


customer

Customer complaint

Delay and production delivery

0077

Order Handling
(Export)

Checking of stock
availability from QC
warehouse.

Exposure to dust

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

0078

Order Handling
(Export)

Encoding to Job Order


then printing and signing
Job Order

Wrong encoding of job orders

Delayed delivery

MEDIUM

-Double checking of FVC


ECA-SAM002 Job Order vs. FKC Job
Order

Account
Executive, Sales
and Marketing
Manager

0079

Order Handling
(Export)

Encoding to Job Order


then printing and signing
Job Order

Exposure to computer radiation

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

0080

Prospecting

Creating list of prospective


Exposure to computer radiation
customer

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

0081

Prospecting

Identification and
qualification of potential
customer

Exposure to computer radiation

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

0082

Prospecting

Presentation and
demonstration

Exposure to dust, heat and others.

illness/discomfort

MEDIUM

ECA-SAM004

Annual physical
examination

Account
Executive, Sales
and Marketing
Manager

0083

Prospecting

Handling objections and


closing

Incapability of closing the deal

No new customer

MEDIUM

-Cover n action plans for


SWOT Analysis for SAM
ECA-SAM009 -Additional headcount Manager and Engineer
-API, UL, FM certification

Account
Executive, Sales
and Marketing
Manager

0084

Delivery(Local &
Export)

Receipt of delivery
schedule from Production
Manager

Unable to schedule the delivery

Delay of delivery to the


customer

MEDIUM

-Constant monitoring of
required delivery date of
customers
ECA-SAM005
-Established procedure
for handling customer
complaints

Account
Executive, Sales
and Marketing
Manager

0085

Delivery(Local &
Export)

Receipt of delivery
schedule from Production
Manager

Late receipt of advice

Delay of delivery to the


customer

MEDIUM

ECA-SAM005

-Constant monitoring of
required delivery date of
customers
-Established procedure
for handling customer
complaints

Account
Executive, Sales
and Marketing
Manager

0086

Delivery(Local &
Export)

Scheduling and
determination of delivery
destination

Unable to schedule the delivery

Delay of delivery to the


customer

MEDIUM

-Constant monitoring of
ECA-SAM005 required delivery date of
customers

Account
Executive, Sales
and Marketing
Manager

0087

Delivery(Local &
Export)

Scheduling and
determination of delivery
destination

Unable to schedule the delivery

Customer complaint

MEDIUM

-Established procedure
ECA-SAM005 for handling customer
complaints

Account
Executive, Sales
and Marketing
Manager

0088

Delivery(Local &
Export)

Preparation and signing


sales documents

Exposure to computer radiation

Eye irritation/discomfort

MEDIUM

ECA-SAM003

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

0089

Delivery(Local &
Export)

Endorse container/hauler
to Production Manager for Overweight load
loading

Penalty to the shipping line

MEDIUM

-Confirmation from
Production Manager of
actual weight of the
items for delivery
-Double checking of
ECA-SAM006
documents needed for
delivery
-Established procedure
for handling customer
complaints

Account
Executive, Sales
and Marketing
Manager

Account
Executive, Sales
and Marketing
Manager

0090

Delivery(Local &
Export)

Endorse container/hauler
to Production Manager for Overweight load
loading

delay delivery to the customer

MEDIUM

-Confirmation from
Production Manager of
actual weight of the
items for delivery
-Double checking of
ECA-SAM006
documents needed for
delivery
-Established procedure
for handling customer
complaints

0091

Delivery(Local &
Export)

Delivery

Reckless driving

Major injury

MEDIUM

ECA-GSD009

0092

Delivery(Local &
Export)

Exposure to computer
radiation

Exposure to computer radiation

Eye irritation/discomfort

MEDIUM

ECA-SAM003

0093

Collection

Preparation and
monitoring of aging
Customer transferred to another place
schedule of AR trade then
waiting for due date

receivables may not be


collected

MEDIUM

ECA-SAM010 Filing of legal action

Account
Executive, Sales
and Marketing
Manager

0094

Collection

Preparation and
monitoring of aging
Customer failure to pay on due date
schedule of AR trade then
waiting for due date

business loss

MEDIUM

ECA-SAM010 Filing of legal action

Account
Executive, Sales
and Marketing
Manager

0095

Collection

Follow-up of collection
Customer does not have the invoice
(Sending delinquency/SA)

delay in collection

MEDIUM

Meeting with customers


ECA-SAM011 for scheduled payment
date and settlement

Sales and
Marketing
Manager

0096

Collection

Follow-up of collection
Sales invoice different from customer PO
(Sending delinquency/SA)

delay in collection/possible
business loss

MEDIUM

Meeting with customers


ECA-SAM011 for scheduled payment
date and settlement

Sales and
Marketing
Manager

0097

Collection

Sending delinquency
report (preparation of
legal action)

Legal expenses

business loss

MEDIUM

Meeting with customers


ECA-SAM011 for scheduled payment
date and settlement

Sales and
Marketing
Manager

0098

Customer
Accreditation

Receipt of accomplished
Customer Information
Sheet

Failure of customer to inform updates

business loss

MEDIUM

ECA-SAM012

-Inform customer
-Constant follow-ups

Sales and
Marketing
Manager

0099

Customer
Accreditation

Update of customer
database

New customer is added to the existing


database

Incomplete analysis report of


potential customer

MEDIUM

ECA-SAM013

-Inform customer
constant follow-ups

Sales and
Marketing
Manager

MEDIUM

-Implementation of 5S
and records management
-Established standard
procedure for control of
documents
-Signing of process
owners who received the
documents
ECA-PRD001
-follow up through email
folder per palletainer bin control
-monthly inventory based
on stock card record
-Establish procedure for
handling customer
complaint

0100

Production Planning

Review of JO and drawing


Overlook of job orders and specifications
from Sales Department

Loss of customers

Annual eye examination,


use of eyeglasses

Account
Executive, Sales
and Marketing
Manager

Production
Manager

-Coordinate with FKC through


GM in relation to the early
submission of JOB Orders
together with the drawings
-Monthly physical inventory to
be done to address inventory
inaccuracy
-additional manpower to
support physical inventory
and other QCD activities

Production
Manager

0101

Production Planning

Review of JO and drawing


Late issuance of JO
from Sales Department

delay in delivery/customer
complaint

MEDIUM

-Implementation of 5S
and records management
-Established standard
procedure for control of
documents
-Signing of process
owners who received the
documents
ECA-PRD001
-follow up through email
folder per palletainer bin control
-monthly inventory based
on stock card record
-Establish procedure for
handling customer
complaint

Production
Manager

Production
Manager

-Coordinate with FKC through


GM in relation to the early
submission of JOB Orders
together with the drawings
-Monthly physical inventory to
be done to address inventory
inaccuracy
-additional manpower to
support physical inventory
and other QCD activities

Production
Manager

-Coordinate with FKC through


GM in relation to the early
submission of JOB Orders
together with the drawings
-Monthly physical inventory to
be done to address inventory
inaccuracy
-additional manpower to
support physical inventory
and other QCD activities

Production
Manager

0102

Production Planning

Review of JO and drawing


delay in delivery/customer
No drawing received from Sales Department
from Sales Department
complaint

MEDIUM

-Implementation of 5S
and records management
-Established standard
procedure for control of
documents
-Signing of process
owners who received the
documents
ECA-PRD001
-follow up through email
folder per palletainer bin control
-monthly inventory based
on stock card record
-Establish procedure for
handling customer
complaint

0103

Production Planning

Review of inventory of
items from
Japan(Furukawa Kogyo)

MEDIUM

ECA-PRD002

-Establish procedure for


handling customer
complaint
-Comply with summary of
Job Orders (internal
control)

Production
Manager

Production Planning

Review of inventory of
items from
Japan(Furukawa Kogyo)

MEDIUM

-Establish procedure for


handling customer
complaint
ECA-PRD002
-Comply with summary of
Job Orders (internal
control)

Production
Manager

MEDIUM

-5S, established
procedure for control of
documents
-established procedure
for production planning
ECA-PRD003
-checking of inventory
items
-Established procedures
for handling of customer
complaints

Production
Manager

-Monthly physical inventory to


be done to address inventory
inaccuracy
-additional manpower to
support physical inventory
and other QCD activities

Production
Manager

MEDIUM

-5S, established
procedure for control of
documents
-established procedure
for production planning
ECA-PRD003
-checking of inventory
items
-Established procedures
for handling of customer
complaints

Production
Manager

-Monthly physical inventory to


be done to address inventory
inaccuracy
-additional manpower to
support physical inventory
and other QCD activities

Production
Manager

0104

0105

0106

Production Planning

Production Planning

Review of inventory of
items in the plant

Review of inventory of
items in the plant

Overlook Furukawa Kogyo's inventory

Loss of customers

Copy of FKC's inventory is not updated

inaccurate forecasting of items


needed

overlook on plant's inventory

Inaccurate inventory of valve parts

delayed delivery

delayed delivery

0107

0108

0109

0110

0111

Production Planning

Production Planning

Production Planning

Production Planning

Production Planning

Ordering from
subcontractor

Ordering from
subcontractor

wrong specification of JO issued

late delivery

Preparation of production
requirement for the month improper workload allocation
(FDY & MCH)

Preparation of production
requirement for the month improper workload allocation
(FDY & MCH)

Distributing schedule to
delay in distribution of production
Production Department
requirements
Head

rejection of items

Customer complaint

high cost of inventory

unable to meet target

delay in delivery

MEDIUM

-Implementation of 5S
and records management
-Established standard
procedure for control of
documents
-Signing of process
owners who received the
documents
ECA-PRD001
-follow up through email
folder per palletainer bin control
-monthly inventory based
on stock card record
-Establish procedure for
handling customer
complaint

Production
Manager

MEDIUM

-Implementation of 5S
and records management
-Established standard
procedure for control of
documents
-Signing of process
owners who received the
documents
ECA-PRD001
-follow up through email
folder per palletainer bin control
-monthly inventory based
on stock card record
-Establish procedure for
handling customer
complaint

Production
Manager

MEDIUM

-review distribution of
workload
-review of accomplished
traceability slip
-regular meeting with
ECA-PRD004
production personnel for
weekly schedule
-Proper review of JO
-Established procedure
on production planning

Production
Manager

MEDIUM

-review distribution of
workload
-review of accomplished
traceability slip
-regular meeting with
ECA-PRD004
production personnel for
weekly schedule
-Proper review of JO
-Established procedure
on production planning

Production
Manager

MEDIUM

-documented procedure
in production planningimmediate endorsement
ECA-PRD008 of job order from sales
-established procedure
for handling of customer
complaints

Production
Manager

0112

0113

0114

Production Planning

Product status

Identification and
Traceability

Preparation of production
schedule for shipping

delay in production processes

rejection of items

MEDIUM

-Review of JO
-Inventory of casting
-regular meeting with
production personnel for
ECA-PRD005
weekly schedule of items
-Established procedure
for handling for customer
complaints

Receipt and encoding


daily production report

exposure to computer radiation

Eye irritation/discomfort

MEDIUM

-Use different type of


computer monitor
ECA-PRD006 -eye examination during
APE
-use of eyeglasses

Production
Manager

Production
Manager

Attaching markings on
pattern (pattern
preparation)

Wrong markings used

rejection of item

MEDIUM

-Issue JO and drawing to


DND
-Confirm markings and
specifications vs. JO and
Drawing
-Regular production
ECA-PRD007 meeting
-Established procedure
and work instruction for
pattern preparation and
checking
-Established procedure
for customer complaints

Production
Manager

0115

Review of drawing and


Pattern and Corebox
checking of pattern and
Preparation
corebox

delayed issuance of pattern

target output not met

MEDIUM

ECA-FDY024

-available drawings
readily withdrawn from
DND
-Issuance of corrective
and preventive action to
concerned section

DND Head,
Pattern
Supervisor

0116

Review of drawing and


Pattern and Corebox
checking of pattern and
Preparation
corebox

Urgent items not listed

Delayed delivery

MEDIUM

ECA-FDY024

-available drawings
readily withdrawn from
DND
-Issuance of corrective
and preventive action to
concerned section

DND Head,
Pattern
Supervisor

MEDIUM

-Check sheet history for


provided to be filled up
whenever the pattern
undergoes repair
-JO with specified
changes on dimensions
ECA-FDY024 and markings are given
to pattern supervisor
-remelting of rejected
items
-issuance of corrective
and preventive action to
concerned section

DND Head,
Pattern
Supervisor

MEDIUM

-Preventive maintenance
is conducted by
maintenance department
-Safety belt and ladder is
ECA-FDY021
used
-availability of company
clinic, nurse and trained
first aiders

Pattern
Supervisor

0117

0118

Review of drawing and


Pattern and Corebox
checking of pattern and
Preparation
corebox

Pattern and Corebox Retrieval of drawing,


Preparation
pattern and corebox

Pattern records not updated

Workers might be hit by falling items

internal rejection

injury/fatality

0119

0120

0121

0122

Pattern and Corebox Retrieval of drawing,


Preparation
pattern and corebox

Pattern and Corebox


Pattern repair
Preparation

Pattern and Corebox


Pattern repair
Preparation

Pattern and Corebox


Pattern repair
Preparation

Fire hazards in the pattern storage area

Using and handling cutting tools(rip saw,


band saw, etc.)

Generation of waste (cut wood/saw dust)

Exposure to hazardous materials such as


Araldite and Hardener

loss of property and fatality

Major injury

Air pollution(local)

minor injury

MEDIUM

-Proper storage of
reactive/flammable
materials based on the
study of MSDS - reactivity
data and other related
ECA-FDY002 material properties
-Availability of fire
extinguisher and fire
hydrant
-formation of Fire Brigade
and Emergency Team

Pattern
Supervisor,
Safety
Committee

MEDIUM

-Trade test conducted


prior to hiring
-Safety orientation
required prior to work
-Regular meeting is
conducted(weekly and
monthly)
-Regular preventive
maintenance
-Providing PPEs to all
ECA-FDY001 workers
-Long sleeve uniform
provided to workers
-established monitoring
of busted lamps and
immediate replacement
-availability of company
clinic, nurse and trained
first aiders
-employees are provided
with health card

Pattern
Supervisor,
Safety
Committee

MEDIUM

-utilization of annex area


-dust collecting pan and
container are provided
ECA-FDY028 -regular collection of saw
dust and cut woods
-issuance and usage of
PPE

Pattern
Supervisor,
Safety
Committee

MEDIUM

-Chemicals are place


near window or open
area for good ventilation
-proper ppe is provided
-available spill control
materials and
ECA-FDY039 containment
-orientation of concerned
personnel on raw
material MSDS
-availability of company
clinic, nurse and trained
first aid team

Pattern
Supervisor,
Safety
Committee

Consider installation of dust


collection or exhaust duct to
collect generated saw dust.

Pattern
Supervisor,
Safety
Committee, GM

0123

0124

0125

Pattern and Corebox


Pattern repair
Preparation

Pattern and Corebox


Pattern repair
Preparation

Pattern and Corebox


Preparation

Penetration of foreign body to the eyes

Contact with sharp objects

Checking of gating
system, sprue pop-off,
Failure to re-check pattern
riser, markings, dowel and
wooden box

minor injury

injury

Rejection of casting

MEDIUM

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
-Preventive maintenance
ECA-FDY003 of machines is done
regularly
-Installation of spray mist
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

Pattern
Supervisor,
Safety
Committee

MEDIUM

-Trade test conducted


prior to hiring
-Safety orientation
required prior to work
-Regular meeting is
conducted(weekly and
monthly)
-Regular preventive
maintenance
-Providing PPEs to all
ECA-FDY001 workers
-Long sleeve uniform
provided to workers
-established monitoring
of busted lamps and
immediate replacement
-availability of company
clinic, nurse and trained
first aiders
-employees are provided
with health card

Pattern
Supervisor,
Safety
Committee

MEDIUM

-Check sheet history for


provided to be filled up
whenever the pattern
undergoes repair
-procedure manual and
work instructions are
provided
-JO with specified
ECA-FDY024
changes on dimensions
and markings are given
to pattern supervisor
-remelting of rejected
items
-issuance of corrective
and preventive action to
concerned section

DND Head,
Pattern
Supervisor

Checking of gating
system, sprue pop-off,
Penetration of foreign body to the eyes
riser, markings, dowel and
wooden box

0126

Pattern and Corebox


Preparation

0127

Pattern and Corebox Application of mold


Preparation
release agent

0128

Pattern and Corebox Application of mold


Preparation
release agent

Inhalation of odors/fumes by workers

Presence of flame or fire near the working


area

0129

Pattern and Corebox Application of mold


Preparation
release agent

0130

Pattern and Corebox Endorsement of pattern to


Delayed endorsement
Preparation
molding area

0131

Mold Preparation

Accidental spillage of mold release agent

Checking completeness of
pattern parts and
Incomplete parts or accessories
accessories

minor injury

MEDIUM

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
-Preventive maintenance
ECA-FDY003 of machines is done
regularly
-Installation of spray mist
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

Respiratory illness

MEDIUM

-use of respirator
ECA-FDY019 -regular air quality
monitoring

Pattern
Supervisor,
Safety
Committee

MEDIUM

-Designated areas for


mold release agent used
in pattern repair
-availability of fire
ECA-FDY002
extinguishers and fire
hydrant
-formation of Fire Brigade
and Emergency Team

Pattern
Supervisor,
Safety
Committee

Pattern
Supervisor,
Safety
Committee

Loss of property and fatality

Pattern
Supervisor,
Safety
Committee

Land contamination

MEDIUM

-Awareness of the MSDS


-Specific area for
different material storage
-materials are properly
ECA-FDY018 labeled
-delivered in tin container
--area for the material is
contained
-provision of spill kits

Delayed delivery to customer

MEDIUM

-established lead
time/Production
ECA-FDY025 Schedule/Traceability Slip
-Pattern inventory os
provided

Pattern
Supervisor,
Producton
Manager

MEDIUM

-Pattern check sheet is


accomplished prior to
endorsement to molding
-endorsement slip from
pattern shop and casting
traceability slip are
accomplished and
ECA-FDY031
received accordingly by
pattern and molding
supervisors
-casting traceability slip
and monitoring sheet are
issued to each process
and accomplished

Molding
Leadman,
Foundry Head,
Producton
Manager

Delay in production

-Outsourcing of other jobs not


able to be accomodated by
the patternmaking section
-coordinate with customer for
delivery date adjustment

Overtime utilizaton

Pattern
Supervisor,
Producton
Manager

Molding
Leadman,
Foundry Head,
Producton
Manager

0132

0133

0134

0135

0136

0137

Mold Preparation

Preparation of molding
boxesand/or reinforcement struck by falling object
bars

Mold Preparation

Preparation of molding
boxesand/or reinforcement dropping of load from crane
bars

Mold Preparation

Preparation of molding
boxesand/or reinforcement crane overloading
bars

Mold Preparation

Preparation of molding
boxesand/or reinforcement swinging of crane load
bars

Mold Preparation

Mold Preparation

Preparation of molding
boxesand/or reinforcement crane wheel falling off its rails
bars

Preparation of molding
Shortage of molding boxes and/or
boxesand/or reinforcement
reinforment bars
bars

Major injury

Major injury

Major injury/crane damage

Major injury

Major injury

delay in production

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
Molding
ECA-FDY008
forklift safety operation
Leadman, Molder
-inventory and cheking of
molding box condition
and subsequent repair

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
Molding
ECA-FDY008
forklift safety operation
Leadman, Molder
-inventory and cheking of
molding box condition
and subsequent repair

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
Molding
ECA-FDY008
forklift safety operation
Leadman, Molder
-inventory and cheking of
molding box condition
and subsequent repair

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
Molding
ECA-FDY008
forklift safety operation
Leadman, Molder
-inventory and cheking of
molding box condition
and subsequent repair

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
Molding
ECA-FDY008
forklift safety operation
Leadman, Molder
-inventory and cheking of
molding box condition
and subsequent repair

MEDIUM

-Consider gathering data to


Traceability sheet issued
help in efficient scheduling of
to molders for the daily
Production
items to be molded. Make an
schedule of items to be
Manager,
inventory of molding boxes
ECA-FDY045 molded
Foundry Head, and re-bars to serve as an aid
Rescheduling of molding
Molding Leadman during scheduling.
of items not able to be
-Fabricate new molding
molded due to shortage
boxes/rebars

Production
Manager,
Foundry Head,
Molding
Leadman,
Maintenance

-Performing calibration
befor sanding operation
-Panel control indicator
lights up when the unit is
malfunctioning
-regular maintenance of
dust collectors
-WES Machine Daily
ECA-FDY015
Check Sheet is
accomplised proir to
operation
-conttrol usage of
chemical
-installation of sand
reclamation system

Molding
Leadman,
Molder

0138

Mold Preparation

Sanding operation

use of chemicals

costly

MEDIUM

0139

Mold Preparation

Sanding operation

Improper disposal of wastewater and


wetted dust from dust collector

unpleasant surroundings

MEDIUM

ECA-FDY016

MEDIUM

-Provide exclusive
compressor unit for mixer
-Conduct regular
preventive maintenance
on chemical pumps
-Accomplish WES
Machine Daily Check
ECA-FDY032
Sheet
-Presence of Work
Instruction at the work
area
-Regular addition of new
sand
-Replace reject

MEDIUM

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
-Preventive maintenance
Molding
ECA-FDY003 of machines is done
Leadman, Safety
regularly
Committee
-Installation of spray mist
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

0140

0141

Mold Preparation

Mold Preparation

Sanding operation

Sanding operation

Improper calibration ratio

Foreign body contact with eyes

incompletely cured molds,


rejected molds/castings

minor injury

-Daily cleaning of wettype dust collector


-usage of metal container
for wet dust collection
-Use collected wet dust
sa backfill

Consider purchase of sieve


analysis equipment to
monitor and control sand
grain size and adjust resin to
sand ratio accordingly.

Foundry
Engineer,
Purchasing, GM

Consider purchase of
catalyst/resin blending
machine that adjusts catalyst
strength based on sand
temperature in order to
produce quality molds

Foundry
Engineer,
Purchasing, GM

Molding
Leadman,
Molder, Loader
Operator

Molding
Leadman,
Molder,
Maintenance

0142

0143

0144

0145

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Sanding operation

Sanding operation

Sanding operation

Sanding operation

Direct mixing and exposure to chemicals

Person might fall down when stepping on


roller conveyor

Workers might be hit by hanging mixer


when stepping on conveyor

Skin, eye, respiratory & digestive tract


irritation

Explosion/major injury/damage
of company property

minor injury

minor injury

minor injury

MEDIUM

-Proper labeling of
containers
-Posting of work
instruction at the sand
calibration area
-Chemical containers are
located near the window
for good ventilation
-Proper PPE is provided
-Spill response materials
are available
Molding
ECA-FDY019 -containment
Leadman, Safety
-availability of company
Committee
clinic , nurse and first aid
team
-health card is given to
all regular employees
maintenance of company
property
-availability of fire
extinguisher at the work
area
-Issuance of PPE's

MEDIUM

-Provision of stair step


-5S program is
implemented
-implementation of 5S
ECA-FDY030 program
-availability of company
clinic
-provision of health card
for regular employees

MEDIUM

-Discussing incidents
during monthly safety
meeting
-Provision of stair step
Molding
-Health card provided to
ECA-FDY036
Leadman, Safety
each employee
Committee
-Availability of company
clinic
-Trained first aider
available on working area

MEDIUM

Molding
Availability of hospital within
Leadman, Safety
5km radius
Committee

-Chemical is placed near


the window for good
ventilation
-Proper PPE is provided
-available spill contrl
materials and
Molding
containment procedure
ECA-FDY039
Leadman, Safety
orientation on concerned
Committee
personnel on raw
materials MSDS
-availability of company
clinic, nurse, and first aid
team

Molding
Leadman,
Safety
Committee

0146

0147

0148

0149

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Sanding operation

Sanding operation

exposure to silica dust

exposure to silica dust

Ramming of sand mixture Foreign body contact with eyes

Ramming of sand mixture soft ramming

minor injury (skin and eye


irritation)

lung injury (silicosis)

minor injury(eye irritation)

weak mold, casting rejection

MEDIUM

MEDIUM

-Chemical is placed near


the window for good
ventilation
-Proper PPE is provided
-available spill contrl
materials and
Molding
containment procedure
ECA-FDY039
Leadman, Safety
orientation on concerned
Committee
personnel on raw
materials MSDS
-availability of company
clinic, nurse, and first aid
team

-Chemical is placed near


the window for good
ventilation
-Proper PPE is provided
-available spill contrl
materials and
Molding
containment procedure
ECA-FDY039
Leadman, Safety
orientation on concerned
Committee
personnel on raw
materials MSDS
-availability of company
clinic, nurse, and first aid
team

MEDIUM

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
-Preventive maintenance
Molding
ECA-FDY003 of machines is done
Leadman, Safety
regularly
Committee
-Installation of spray mist
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

MEDIUM

-Provide exclusive
compressor unit for mixer
-Conduct regular
preventive maintenance
on chemical pumps
-Accomplish WES
Machine Daily Check
ECA-FDY032
Sheet
-Presence of Work
Instruction at the work
area
-Regular addition of new
sand
-Replace reject

Molding
Leadman,
Molder,
Maintenance

Consider purchase of
catalyst/resin blending
machine that adjusts catalyst
strength based on sand
temperature in order to
produce quality molds

Foundry
Engineer,
Purchasing, GM

0150

0151

0152

0153

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Curing and stripping of


pattern/corebox and visual body parts hit by mallet/hammer
inspection

Curing and stripping of


pattern/corebox and visual mold falls due to poor lifting technique
inspection

Curing and stripping of


pattern/corebox and visual mold falls due to poor lifting technique
inspection

Curing and stripping of


pattern/corebox and visual dropping of load from crane
inspection

minor inury

minor injury

molds rejected

major injury

MEDIUM

-maintaining safe
distance from items for
shakeout
-established work
instructions
ECA-FDY042 -modified handles from
ball type to a more
suitable and durable one
-availability of company
clinic, nurse and trained
first aiders.

Molding
Leadman,
Molder, Safety
Committee

MEDIUM

-Crane operatoin seminar


is given
-Durable chain sling is
used and with strength
certificate provided
-regular preventive
maintenance of crane
ECA-FDY010 -daily checklist
maintenance of crane
-daily checklist of crane
is accomplished prior to
operation
-PPE is provided
-Availability of company
clinic

Molding
Leadman,
Molder, Safety
Committee

MEDIUM

MEDIUM

-Crane operatoin seminar


is given
-Durable chain sling is
used and with strength
certificate provided
-regular preventive
maintenance of crane
ECA-FDY010
-daily checklist
maintenance of crane
-daily checklist of crane
is accomplished prior to
operation
-PPE is provided

Molding
Leadman,
Molder, Safety
Committee

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
forklift safety operation
-inventory and cheking of
molding box condition
Molding
ECA-FDY008
and subsequent repair
Leadman, Molder
-regular preventive
maintenance of crane
and forklift
-checklist of crane prior
to operation

Remolding

Molding
Leadman,
Molder

0154

0155

0156

0157

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Curing and stripping of


pattern/corebox and visual crane overloading
inspection

Curing and stripping of


pattern/corebox and visual swinging of crane load
inspection

Curing and stripping of


pattern/corebox and visual crane wheel falling off its rails
inspection

Transfer of core molds to


coating/setting area

getting struck by forklift

Major injury/crane damage

major injury

major injury

major injury

MEDIUM

MEDIUM

MEDIUM

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
forklift safety operation
-inventory and cheking of
molding box condition
Molding
ECA-FDY008
and subsequent repair
Leadman, Molder
-regular preventive
maintenance of crane
and forklift
-checklist of crane prior
to operation

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
forklift safety operation
-inventory and cheking of
molding box condition
Molding
ECA-FDY008
and subsequent repair
Leadman, Molder
-regular preventive
maintenance of crane
and forklift
-checklist of crane prior
to operation

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
forklift safety operation
-inventory and cheking of
molding box condition
Molding
ECA-FDY008
and subsequent repair
Leadman, Molder
-regular preventive
maintenance of crane
and forklift
-checklist of crane prior
to operation

-competency
requirement for forklift
operator and trade test is
conducted
-seminars and training on
forklift safety operation
-forklift horn, backing
Molding
alarm and side mirrors
Leadman,
ECA-FDY013 are installed
Molder, Forklift
-regular preventive
Operator, Safety
maintenance of forklift
Committee
-forklift checksheet is
accomplished daily by
operator
-painted gutters on the
driveway

-Conduct Forklift Training


-Generate Forklift Training
and certification program,
plan and schedule
-install necessary safety
features of Forklift such as
beacon light or blinkers

HR,
Maintenance,
Safety
Committee

0158

0159

0160

0161

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Mold coating, drying and


visual inspection

Mold coating, drying and


visual inspection

Mold coating, drying and


visual inspection

Mold coating, drying and


visual inspection

Foreign body contact with eyes

dropping hazard when lifting molds

Alcohol catching fire and exploding

Skin, eye, respiratory & digestive tract


irritation

minor injury

mold rejected

major injury, fatality

minor injury

MEDIUM

MEDIUM

HIGH

MEDIUM

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
-Preventive maintenance
ECA-FDY003 of machines is done
regularly
-Installation of spray mist
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

-Crane operatoin seminar


is given
-Durable chain sling is
used and with strength
certificate provided
-regular preventive
maintenance of crane
ECA-FDY010
-daily checklist
maintenance of crane
-daily checklist of crane
is accomplished prior to
operation
-PPE is provided

Pattern
Supervisor,
Safety
Committee

Molding
Leadman,
Molder, Safety
Committee

-Properly designated
working areas as far
away from the melting
and pouring operations
as possible
-secure or cover the
Coating
solution during the
Operator,
ECA-FDY022 pouring process
Foundry Head/
-Conduct monthly safety Engineer, Safety
meeting
Committee
-Availability of fire
extinguishers and
hydrants
-formation of Fire Brigade
and Response Team

-Chemical is placed near


the window for good
ventilation
-Proper PPE is provided
-available spill control
Coating
materials and
Operator,
containment procedure
ECA-FDY039
Foundry Head/
orientation on concerned
Engineer, Safety
personnel on raw
Committee
materials MSDS
-availability of company
clinic, nurse, and first aid
team

Remolding

Molding
Leadman,
Molder

0162

0163

0164

Mold Preparation

Mold Preparation

Mold coating, drying and


visual inspection

Mold repair

Ingestion of methanol

Foreign body contact with eyes

collapse of repaired portion

fatality/blindness

minor injury

casting rejected

MEDIUM

-orientation of concerned
personnel on raw
Coating
materials MSDS
Operator,
ECA-FDY040 -wearing of provided PPE Foundry Head/
-chemicals are properly
Engineer, Safety
labeled
Committee

MEDIUM

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
-Preventive maintenance
ECA-FDY003 of machines is done
regularly
-Installation of spray mist
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

MEDIUM

-presence of Work
Instruction in work area
Molding
-Presence of experienced
Leadman,
supervisor and skiled line
ECA-FDY033
Foundry Head/
leader
Engineer, Safety
-presence of work
Committee
instruction on sand
calibration

Mold Preparation

Mold repair

0165

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

mismatch/loose clamping

casting rejected

MEDIUM

0166

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

Mold might fall from crane

mold rejected

MEDIUM

Molding
Leadman,
Maintenance,
Safety
Committee

-On-job-training,
orientation and close
supervision
-proper clamping of
Setting
molds prior to transfer
ECA-FDY011
Supervisor/
-ensure mold paste has
Operator
dried prior to transfer
-regular inventory of
metal boxes and
reinforcement bars
-Crane operatoin seminar
is given
-Durable chain sling is
used and with strength
certificate provided
-regular preventive
Setting
maintenance of crane
Supervisor/
ECA-FDY010
-daily checklist
Operator, Safety
maintenance of crane
Committee
-daily checklist of crane
is accomplished prior to
operation
-PPE is provided

-Re-casting
-discuss in production
meeting for every major
ocurrence

Remolding

Foundry Head/
Engineer

Molding
Leadman,
Molder

0167

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

Exposure to sparks and splashes

minor injury (burns)

MEDIUM

0168

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

Alcohol catching fire and exploding

major injury, fatality

HIGH

0169

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

Skin, eye, respiratory & digestive tract


irritation

minor injury

MEDIUM

0170

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

dropping of load from crane

major injury

MEDIUM

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

0171

0172

crane overloading

swinging of crane load

Major injury/crane damage

major injury

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

-No mold re-touches by


coating near furnace
during charging
operation
-safety meeting and
ECA-FDY022 awareness
-coating solution must be
secured and no coating
applications near the
area
during are
tapping
-Chemicals
placeand
pouring
near
window or open
area for good ventilation
-proper ppe is provided
-available spill control
materials and
ECA-FDY039 containment
-orientation of concerned
personnel on raw
-Height
of storing
materiallimit
MSDS
molding
boxes
to
-availability
of company
approximately
5 ft.
clinic, nurse and
trained
-Seminars
on crane and
first
aid
team
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Setting
Supervisor/
Operator

Setting
Supervisor/
Operator

Setting
Supervisor/
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Setting
Supervisor/
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Setting
Supervisor/
Operator

Melting
Operator,
Foundry Head/
Engineer

0173

0174

Mold Preparation

Mold Preparation

Mold assembly,
endorsement of
assembled molds to
pouring and recording of
poured molds

Receipt of mold assembly

0175

Mold Preparation

Preparation of raw
materials

0176

Mold Preparation

Preparation of raw
materials

0177

Mold Preparation

Preparation of raw
materials

crane wheel falling off its rails

Assembled molds are short of set target


quantity

major injury

Wastage of electric power

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

MEDIUM

-accomplishment of
ECA-FDY017 casting traceability slip
for each process.

Setting
Supervisor/
Operator

Setting
Supervisor/
Operator,
Coating
Operator, Molder,
Foundry
Head/Engineer

-competency
requirement for forklift
operator and trade test is
conducted
-seminars and training on
forklift safety operation
-forklift horn, backing
alarm and side mirrors
Forklift Operator,
ECA-FDY013 are installed
Safety
-regular preventive
Committee
maintenance of forklift
-forklift checksheet is
accomplished daily by
operator
-painted gutters on the
driveway

Getting struck by forklift

Major injury

MEDIUM

Dust emission/smoke emission

ill health/ air polution

MEDIUM

-use of respirator
ECA-FDY019 -regular air quality
monitoring

Melting
Leadman/
Operator, Safety
Committee

MEDIUM

-Trade test conducted


prior to hiring
-Safety orientation
required prior to work
-Regular meeting is
conducted(weekly and
monthly)
-Regular preventive
maintenance
-Providing PPEs to all
ECA-FDY003 workers
-Long sleeve uniform
provided to workers
-established monitoring
of busted lamps and
immediate replacement
-availability of company
clinic, nurse and trained
first aiders
-employees are provided
with health card

Meltin g
Leadman/
Operator, Safety
Committee

Foreign body contact with eyes

Minor injury

-Conduct Forklift Training


-Generate Forklift Training
and certification program,
plan and schedule
-install necessary safety
features of Forklift such as
beacon light or blinkers

HR,
Maintenance,
Safety
Committee

0178

0179

0180

0181

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Metal charging

Metal charging

Metal charging

Metal charging

Potential explosion

Penetration of metal to cooling system


causing explosion

Use of electricity for the furnace

Use of raw material(scrap)

Single to multiple fatality

Single to multiple fatality/ loss


of property

Depletion of resources/ high


production costs

Depletion of resources

MEDIUM

-shaded scrap area to


avoid wet metal charges Baling Operator,
-material segregation and
Purchasing ,
presence of baling
Warehouse,
ECA-FDY026
machine
Melting
-accredited scrap
Leadman/
supplier
operator

MEDIUM

-order lining materials


only from accredited
supplier
-Operator on-the-job
training
-monitor number of heats
per lining installation
-built-in sensor on the
Melting
furnace lining that can
Leadman/
Presence of another furnace
detect penetration
Operator,
ECA-FDY004
which can be used
-preventive maintenance
Mainenance
immediately
conducted regulalry
Personnel, Safety
-electric furnace
Committee
monitoring sheet is
accomplished every
charge
-orientation of melting
operator vis-a-vis furnace
maintenance and
operation

MEDIUM

-periodic preventive
maintenance of furnaces
-daily checksheet for
electric furnace
monitoring
-skilled operator/
presence of work
instruction
-baled steel scrap to
hasten cahrging and
melting
-accomplishment of
ECA-FDY017
casting traceability slip
for each process.
-preventive maintenance
of crane and other
machines
-review of previous
performance during
Departmental Meeting
-Continuous melting
operation
-monitoring kWh per kg
of metal

Melting
Leadman/
Operator,
Maintenance,
Foundry
Head/Engineer

MEDIUM

-production scheduling
based on cutomer
requirement and stock
level
-use of casting
traceability slip
-established cost
ECA-FDY020 reduction program
through review of
monthly inventory and
consumption reports
-recycling of metal
splashes and fins
-remelting of reject
castings

Melting
Leadman/
Operator,
Foundry
Head/Engineer,
Production
Manager

Melting
Leadman/
Operator,
Foundry Head/
Engineer

0182

0183

0184

0185

0186

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Metal charging

Metal charging

Metal charging

Metal charging

Metal charging

Smoke emission (furnace)

Exposure to sparks and splashes

dropping of load from crane

swinging of crane load

crane wheel falling off its rails

air pullution/ minor discomfort

Burns, minor injury

major injury

major injury

major injury

Melting
Leadman/
Operator,
Maintenance,
Safety
Committee,
Pollution Control
Officer

MEDIUM

-dust hood is installed


-se of masks and
ECA-FDY019 respirators
-regular air quality
monitoring

MEDIUM

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Melting
Leadman/
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Melting
Leadman/
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Melting
Leadman/
Operator

Melting
Operator,
Foundry Head/
Engineer

0187

0188

0189

Mold Preparation

Mold Preparation

Mold Preparation

Metal charging

Exposure to sparks and splashes

Checking the composition Use of electricity for the furnace during


of molten metal
holding time

Checking the composition


Exposure to sparks and splashes
of molten metal

Burns, minor injury

depletion of resources

Burns, minor injury

MEDIUM

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

MEDIUM

-periodic preventive
maintenance of furnaces
-daily checksheet for
electric furnace
monitoring
-skilled operator/
presence of work
instruction
-baled steel scrap to
hasten cahrging and
melting
-accomplishment of
ECA-FDY017
casting traceability slip
for each process.
-preventive maintenance
of crane and other
machines
-review of previous
performance during
Departmental Meeting
-Continuous melting
operation
-monitoring kWh per kg
of metal

MEDIUM

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

Melting
Operator,
Foundry Head/
Engineer

Melting
Leadman/
Operator,
Maintenance,
Foundry
Head/Engineer

Melting
Operator,
Foundry Head/
Engineer

0190

0191

0192

Mold Preparation

Mold Preparation

Mold Preparation

Preheating of ladles

Preheating of ladles

Preheating of ladles

Smoke emission

dropping of load from crane

swinging of crane load

air pollution

major injury

major injury

Melting
Leadman/
Operator,
Maintenance,
Safety
Committee,
Pollution Control
Officer

MEDIUM

-dust hood is installed


-se of masks and
ECA-FDY019 respirators
-regular air quality
monitoring

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Melting
Leadman/
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Melting
Leadman/
Operator

Melting
Leadman/
Operator

0193

Mold Preparation

Preheating of ladles

crane wheel falling off its rails

major injury

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

0194

Mold Preparation

Chill testing

Failure to conduct chill test

hard casting

MEDIUM

ECA-FDY034

MEDIUM

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

0195

Mold Preparation

Chill testing

Exposure to sparks and splashes

Burns, minor injury

-presence of work
instruction in the working
area

Melting
Leadman/
Operator

Replace rejected casting

Foundry Head/
Engineer

Melting
Operator,
Foundry Head/
Engineer

0196

Mold Preparation

Temperature checking

Temperature too high

Wastage of resources and


electricity

MEDIUM

-Replace thermocouple
-re-charge periodically
-presenceof work
instructoin and standard
temperature
ECA-FDY035
-regular external
calibratoin of pyrometer
-orientation of concerned
workers regarding the
handling of pyrometer

0197

Mold Preparation

Charging of inoculant/
spheroidizer

wrong sequence of chraging

hard casting

MEDIUM

Predsence of work
ECA-FDY034 instruction in the working
area

0198

Mold Preparation

Charging of inoculant/
spheroidizer

0199

Mold Preparation

Tapping molten metal into


Metal spillage from the ladle
the ladle

0200

Mold Preparation

Exposure to sparks and splashes

Tapping molten metal into


Exposure to sparks and splashes
the ladle

Melting
Leadman/
Operator, QC
Inspector

Foundry
Head/Engineer

-Switch off furnace power


-Wait for temperatre to go
down

Burns, minor injury

MEDIUM

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

Major injury

MEDIUM

-provide in-house training


Melting
for melter/pourer
Leadman/
ECA-FDY027 -regular claning and
Operator, Pouring
replacement of ladle
Operator
lining

MEDIUM

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

Burns, minor injury

Melting
Leadman/
Operator,
Foundry Head/
Engineer

Melting
Operator,
Foundry Head/
Engineer

Melting
Operator,
Foundry Head/
Engineer

0201

0202

0203

0204

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Pouring molten metal into


Molten metal runout from the mold
molds

Pouring molten metal into


Ladle collapsing from crane
molds

Pouring molten metal into


Pouring at high temperature
molds

Pouring molten metal into Pouring below the standard pouring


molds
temperature

temporary disability, rejected


castings

Fatality

Sand fusion, Rejected castings

Rejected castings

MEDIUM

-established work
instructions to ensure
consistent mold strength
-correct and proper
gating system
-dowel dimension is
Setting
checked
Supervisor/
-mold paste evaluated by Operator, Pouring
ECA-FDY005 QIT and approved for use
Operator,
-regular checking of
Foundry Head/
flatness of molding
Engineer, Safety
boards
Committee
-remelting of rejected
castings
-discussion on rejection
included in weekly
production meeting

MEDIUM

-awareness of cranes
maximum capacity
-ladle has different size
Setting
according to capacity
Supervisor/
-regular preventive
Operator, Melting
maintenance of crane
Leadman/
ECA-FDY006 -training on crane safety Operator, Pouring
operation
Operator,
-checklist for crane prior Foundry Head/
to operation
Engineer, Safety
-issuance of work order
Committee
to maintenance when
abnormalities occur

MEDIUM

-Replace thermocouple
-re-charge periodically
-presenceof work
instructoin and standard
temperature
ECA-FDY035
-regular external
calibratoin of pyrometer
-orientation of concerned
workers regarding the
handling of pyrometer

Melting
Leadman/
Operator, QC
Inspector

MEDIUM

-presence of work
instructions on the work
area
-ladle preheating
-checking and meeting
required temperature
ECA-FDY007 before tapping
-making multiple-cavity
patternsfor small items
-remelting
-discussion on rejection
included in weekly
production meeting

Setting
Supervisor,
Pouring Operator,
Melting
Leadman/
Operator,
Foundry Head/
Engineer

Wait for temperature to go


down

Pouring
Operator,
Foundry Head/
Engineer

0205

0206

0207

0208

0209

0210

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Pouring molten metal into


dropping of load from crane
molds

Pouring molten metal into


swinging of crane load
molds

Pouring molten metal into


crane wheel falling off its rails
molds

Pouring molten metal into


Exposure to sparks and splashes
molds

Endorsement of poured
molds to shakeout

Endorsement of poured
molds to shakeout

dropping of load from crane

swinging of crane load

major injury

major injury

major injury

Burns, minor injury

major injury

major injury

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
Setting
-Seminars on crane and
Supervisor/
ECA-FDY008
forklift safety operation Operator, Pouring
-inventory and cheking of
Operator
molding box condition
and subsequent repair

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
Setting
-Seminars on crane and
Supervisor/
ECA-FDY008
forklift safety operation Operator, Pouring
-inventory and cheking of
Operator
molding box condition
and subsequent repair

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
Setting
-Seminars on crane and
Supervisor/
ECA-FDY008
forklift safety operation Operator, Pouring
-inventory and cheking of
Operator
molding box condition
and subsequent repair

MEDIUM

-provide cover for flow


coat machine to be used
during pouring
-established work
instruction for mold
Setting
assembly which includes
Supervisor/
preheating of molds
Operator, Pouring
before setting
Operator, Melting
-established work
Reject poor quality scrap pr
Operator,
ECA-FDY041 instruction for scrap
returns that may cause
Coating
press which includes
splashing when charged
Operator,
safekeeping of prepared
Foundry Head/
scrap
Engineer, Safety
-issuance of PPE (face
Committee
shield, thermal gloves,
apron - meters/pourers)
-Availability of company
clinic, nurse and trained
first aiders

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
Setting
-Seminars on crane and
Supervisor/
ECA-FDY008
forklift safety operation Operator, Pouring
-inventory and cheking of
Operator
molding box condition
and subsequent repair

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
Setting
-Seminars on crane and
Supervisor/
ECA-FDY008
forklift safety operation Operator, Pouring
-inventory and cheking of
Operator
molding box condition
and subsequent repair

Melting
Operator,
Foundry Head/
Engineer

0211

Mold Preparation

Endorsement of poured
molds to shakeout

crane wheel falling off its rails

major injury

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
Setting
-Seminars on crane and
Supervisor/
ECA-FDY008
forklift safety operation Operator, Pouring
-inventory and cheking of
Operator
molding box condition
and subsequent repair

0212

Mold Preparation

Evaluating furnace
condition

Exposure to silica dust (refractory)

silicosis

MEDIUM

ECA-FDY039

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Shakeout
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Shakeout
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Shakeout
Operator

Shakeout
Operator

0213

Mold Preparation

Receipt of poured molds


and extraction of castings dropping of load from crane
from molds

major injury

-provision of proper PPE


Foundry
-Orientation of concerned Head/Engineer,
personnel on raw
Safety
material MSDS
Committee

Mold Preparation

Receipt of poured molds


and extraction of castings swinging of crane load
from molds

Mold Preparation

Receipt of poured molds


and extraction of castings crane wheel falling off its rails
from molds

0216

Mold Preparation

Receipt of poured molds


and extraction of castings crane overloading
from molds

Major injury/crane damage

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

0217

Mold Preparation

Receipt of poured molds


and extraction of castings Exposure to silica dust (refractory)
from molds

silicosis

MEDIUM

ECA-FDY039

-provision of proper PPE


Foundry
-Orientation of concerned Head/Engineer,
personnel on raw
Safety
material MSDS
Committee

0218

Mold Preparation

Receipt of poured molds


and extraction of castings Exposure to silica dust (refractory)
from molds

minor injury

MEDIUM

ECA-FDY039

-provision of proper PPE


Foundry
-Orientation of concerned Head/Engineer,
personnel on raw
Safety
material MSDS
Committee

0214

0215

major injury

major injury

0219

0220

0221

0222

Mold Preparation

Mold Preparation

Mold Preparation

Mold Preparation

Receipt of poured molds


and extraction of castings body parts hit by mallet/hammer
from molds

Removal of adhering sand


dropping of load from crane
from the castings

Removal of adhering sand


swinging of crane load
from the castings

Removal of adhering sand


crane wheel falling off its rails
from the castings

minor injury

major injury

major injury

major injury

MEDIUM

-maintaining safe
distance from items for
shakeout
-established work
instructions
ECA-FDY042 -modified handles from
ball type to a more
suitable and durable one
-availability of company
clinic, nurse and trained
first aiders.

Molding
Leadman,
Molder, Safety
Committee

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Shakeout
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Shakeout
Operator

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

Shakeout
Operator

Shakeout
Operator

0223

Mold Preparation

Removal of adhering sand


crane overloading
from the castings

Major injury/crane damage

MEDIUM

-Height limit of storing


molding boxes to
approximately 5 ft.
-Seminars on crane and
ECA-FDY008
forklift safety operation
-inventory and cheking of
molding box condition
and subsequent repair

0224

Mold Preparation

Receipt of poured molds


and extraction of castings Exposure to silica dust (refractory)
from molds

minor injury

MEDIUM

ECA-FDY039

-provision of proper PPE


Foundry
-Orientation of concerned Head/Engineer,
personnel on raw
Safety
material MSDS
Committee

lung injury (silicosis)

MEDIUM

ECA-FDY039

-provision of proper PPE


Foundry
-Orientation of concerned Head/Engineer,
personnel on raw
Safety
material MSDS
Committee

0225

Receipt of poured molds


Shakeout and Cleaning and extraction of castings Exposure to silica dust (refractory)
from molds

0226

0227

0228

0229

Shakeout and Cleaning

Shakeout and Cleaning

Shakeout and Cleaning

Hammering off excess


metal on the casting

Hammering off excess


metal on the casting

Hammering off excess


metal on the casting

Transfer of sand/lumps to
Shakeout and Cleaning sand stock area and
primary blasting

Foreign body contact with eyes

Finger hit by casting

Body parts hit by chips or other casting


parts during hammering

Dust and fume emission

minor injury

minor injury

minor injury

ill health/localized air pollution

MEDIUM

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
-Preventive maintenance
Shakeout
ECA-FDY003 of machines is done
Operator, Safety
regularly
Committee
-Installation of spray mist
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

MEDIUM

-maintaining safe
distance from items for
shakeout
-established work
instructions
Shakeout
ECA-FDY042 -modified handles from
Operator, Safety
ball type to a more
Committee
suitable and durable one
-availability of company
clinic, nurse and trained
first aiders.

-Consider use of hard plastic


face shields for operators that
perform hammering activities
Shakeout
-establish safe distance that
Operator, Safety
operators other than the one
Committee
doing the hammering should
be at during such activities
-install dividers

MEDIUM

-Use of PPE to protect or


ECA-FDY046 minimize the force from
flying objects

MEDIUM

-preventive maintenance
of machines
-regular maintenance of
Blastin Machine
dust collector
Operator,
-use of industrial fan
ECA-FDY012
Maintenance,
-dust masks and earplugs
Safety
are issued to employees
Committee
-regular disposal of dust
in the dust collector
machine

Safety
Committee

0230

Transfer of sand/lumps to
Shakeout and Cleaning sand stock area and
primary blasting

Foreign body contact with eyes

minor injury

MEDIUM

0231

Transfer of sand/lumps to
Shakeout and Cleaning sand stock area and
primary blasting

Slipping due to steel shot balls/ sand lumps


minor injury
on the floor

MEDIUM

0232
0233
0234
0235
0236
0237
0238
0239
0240
0241
0242
0243
0244
0245
0246
0247
0248
0249
0250
0251
0252
0253
0254
0255
0256
0257
0258
0259
0260
0261
0262
0263
0264
0265
0266
0267
0268
0269
0270
0271
0272
0273
0274
0275
0276
0277
0278
0279
0280
0281
0282
0283

-Adequate
implementation of
wearing PPE. Proper
selection of PPE for
different natures of work
in the plant
-Good Housekeeping
program
Blastin Machine
-Preventive maintenance
Operator,
ECA-FDY003 of machines is done
Maintenance,
regularly
Safety
-Installation of spray mist
Committee
-Spraying of water on
floor twice daily
-installation of dividers at
grinding area
-availability of company
clinic, nurse and first aid
team

0284
0285
0286
0287
0288
0289
0290
0291
0292
0293
0294
0295
0296
0297
0298
0299
0300
0301
0302
0303
0304
0305
0306
0307
0308
0309
0310
0311
0312
0313
0314
0315
0316
0317
0318
0319
0320
0321
0322
0323
0324
0325
0326
0327
0328
0329
0330
0331
0332
0333
0334
0335
0336
0337
0338
0339
0340
0341
0342
0343
0344
0345
0346
0347
0348
0349
0350
0351
0352
0353
0354
0355
0356
0357
0358
0359
0360
0361

0362
0363
0364
0365
0366
0367
0368
0369
0370
0371
0372
0373
0374
0375
0376
0377
0378
0379
0380
0381
0382
0383
0384
0385
0386
0387
0388
0389
0390
0391
0392
0393
0394
0395
0396
0397
0398
0399
0400
0401
0402
0403
0404
0405
0406
0407
0408
0409
0410
0411
0412
0413
0414
0415
0416
0417
0418
0419
0420
0421
0422
0423
0424
0425
0426
0427
0428
0429
0430
0431
0432
0433
0434
0435
0436
0437
0438
0439

0440
0441
0442
0443
0444
0445
0446
0447
0448
0449
0450
0451
0452
0453
0454
0455
0456
0457
0458
0459
0460
0461
0462
0463
0464
0465
0466
0467
0468
0469
0470
0471
0472
0473
0474
0475
0476
0477
0478
0479
0480
0481
0482
0483
0484
0485
0486
0487
0488
0489
0490
0491
0492
0493
0494
0495
0496
0497
0498
0499
0500