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L
Ref. No.

Hazard Description

Relevant Activities

Source

Top Event

Threat

Consequence

RISK RANKING ACCORDING TO RAM

R
L
C
R
L
C
R

E (I)

Threat Barriers / Recovery Controls

Barrier
Effectiveness

Risk

Storage of Material

competent personnel (rigger, supervisor, crane

operator), quarterly inspection of lifting gears,
crane moving alarm, avoid being under
suspended load, use of passageway for material
2
transfer, lifting height for item >6tons is 0.5m,
PPE, daily check on magnetic lifter, use sufficient
quantity of magnetic lifters for different plate
sizes/weight

Effective

1 B

competent forklift operator , valid forklift

equipment pass, forklift moving beacon light,, use
of passageway for material transfer, lifting height
Effective
1
as low as possible to ground level, PPE, daily
forklift inspection, limit material length & weight
according to forklift capacity

1 B

Wear leather gloves, proper barricade by using

1 barricade tape/floor marking/scaffolding tube
barricade/sharp edge protection

Effective

1 A

1 B

Wear dust mask and eye protection , daily

housekeeping

Effective

2 A

1 A

use safety glasses , install protective

screen/curtain

Effective

2 D

1 A

1 A

1 wear hearing protection

Effective

2 D

1 A

1 A

use proper signage, paint marking, emergency

switch

Effective

2 D

1 C

1 A

use approved respirator & proper ventilation

system

Partially Efctv.

injury & fatality

2 D

1 A

1 A

wear insulating gloves, shoes and clothing. Keep

equipments in dry condition.

Effective

body injury

1 B

1 A

1 A

1 wear proper shoes, keep rails in dry condition.

Effective

dropped item

wrong method of lifting,

undersize wire/lifting belt, faulty
damage to machine and
lifting gears, incompetent rigging
material, bodily injury,
personnel, special lifting tool not
fatality
properly installed, inadequate
magnetic lifter contact surface

item slip & drop

wrong method of lifting,

incompetent operator, improper
fork position, transferring of
oversize plate,

damage to material &

equipment, bodily injury,
fatality

2 C

1 A

steel material

cut or poke by sharp edges

improper barricade for plate

storage

hand & finger injury

2 C

1 A

steel material

machineries expose to dust

from rusty steel plates

blowing of dust, dusty parts

respiratory problem, eye

injury,

2 C

Hot spatter & chipped

plasma arc/flame cutting
slag

cutting

flying debris

skins burn & eyes injury

2 D

Plasma arc sounds

plasma arc cutting

plasma arc

expose to high noise

loss of hearing

Mechanical injury

gear rotation

moving parts such as rotor, rail

roller & gear mechanism

crush or pinch during operation

inadequate safety signage

injury

hazard to health

Items being lifted

transferring of material,
loading & unloading using
lifting of plates & steel material
cranes from/onto
lorry/transporter

Items being transferred

transferring of material,
loading & unloading using
lifting of plates & steel material
forklift from/onto
lorry/transporter

Sharp edges

Dust from rusty steel

plates

transferring of material,
loading & unloading by
using cranes/forklift,
storage area

2 C

1 A

1 B

CNC Cutting Line

inadequate PPE, nonprotective screen/curtains
install
prolong exposure to high
noise,

Fume

plasma arc/flame cutting

coated surface or base material

characteristic

hazardous fume

improper ventilation systems

to remove fume during
operation

Hazardous voltages

plasma arc/flame cutting

machine

CNC plasma/gas cutting machine

flow control box/power
source/plasma torch

contact with live part

improper gloves, shoes &

clothing

Slippery

plasma arc/flame cutting

machine

longitudinal rail

fall

improper shoes, oily rail,

inadequate safety signage
improper secure hoses
connection. Use different type
of fitting on gas hoses.

1 C

1 C

1 A

daily inspections, maintain hoses and fittings in

1 good condition, gas valves closed when not in
use.

Effective

blowing of dust, dusty air filter respiratory problem, eye

or parts
injury,

2 C

1 C

1 A

wear dust mask and eye protection , barricade the

Effective
1 area to prevent unauthorized personnel, daily
housekeeping

Inappropriate lens shade

(safety glasses) & lack of
safety awareness

eyes & skins injury

2 A

1 A

1 A

Partially Efctv.

inadequate PPE

skins burn

2 A

1 A

1 A

1 wear leather gloves & allow metal time to cool

Effective

sudden splash of oil at initial

environmental pollution,
opening, inadequate size of drip
slippery floor
tray, improper placing of drip tray

2 A

1 D

1 A

1 make available (standby) of oil dispersant

Partially Efctv.

slip and fall

poor housekeeping, spill

injury

1 A

1 C

1 A

regular cleaning of work place, placement of oil

1 containment , ensure availability of saw dust,
cloth/rags,

Effective

debris from steel material being

compress on sharp edge

expose to dust & flying particles

working in congested area,

insufficient PPE,

eye injury, respiratory

problem

1 A

1 A

1 C

1 ventilation, adequate eye protection, wear long sleeves Effective

partial loss of hearing,

1 A

1 A

1 A

1 wear PPE (ear plug/ear muff),

Effective

arc eyes (conjunctivitis)

2 A

1 A

1 A

1 cream, wash eyes after coming from welding area

Partially Efctv.

Partially Efctv.

Effective

1 provide sufficient ventilation, welding apron, proper PPE Effective

Hoses and fitting

connections

plasma arc/flame cutting

machine

conc. plasma/gas cutting machine

flammable gases caught on

fire

Dust

storage and during

operation

construction activities, steel

material

expose to dust during

construction activities

Plasma arc rays

plasma arc cutting

open plasma arc

expose to arc flash/intense light

Hot steel material

cutting

plasma arc/flame, heated metal

opening of drain plug

hydraulic oil tubing, drain plug

oil spill

mechanical components

direct contact with hot metal

damage to material &

equipment, bodily injury,
fatality

install protective screen/curtains to reduce

ultraviolet & use correct PPE

T-Bar Fabrication Line

Hydraulic oil

Grease

use correct size of drip tray, immediate cleaning of spill,

wear approved dust respirator, adequate local exhaust

Metal dust & flying

particle

edge rounding machine

Noise from fume suction

fume suction for cleaning

purpose

vacuum

expose to high noise from vacuum vacuum, prolong exposure to

system
high noise, working long hours

Intense light / ray

welding

arc

expose to intense light /arc

looking directly to intense light

without UV protection glasses,
wrong lenses

contact with live part

leak current, poor earthing for

the welding machine, damaged
cable insulation, cables
submerged in water

electrocution, fire, fatality

2 E

2 A

1 C

inspect cables & equipment and connection visually

before energizing, periodic inspection for cables and
equipment, provide proper earthing to ground, use of
1 cable hanger to avoid cable submerged in water, Ensure Effective
availability of fire extinguisher, segregate cables and
gas hoses

welding confined space,

inadequate ventilation

respiratory system problem,

metal fume fever

2 A

1 D

1 A

1 mask,

hot slag and spatters landing on

combustibles materials and/or
human body

inadequate PPE, improper

protection cover

fire, skin burn

1 D

1 A

1 A

1 Fire fighting equipment available nearby, provide

expose to heat

working too long in enclosed

heated area

heat stroke, fire

1 C

2 A

1 C

High current

welding

welding power source

Welding fumes

welding

welding flux, shielding gas, coated

expose to welding fumes
metal surface,

Hot slag, flying spatters

welding

welding

Heat

welding

arc and heated weldment

shirt, wash hands, face & neck after coming from site

wear ultraviolet light eye protection , use UV skin barrier

provide continuous ventilation, wear suitable approved

remove combustible material nearby, adequate PPE,

additional protection cover/tray, housekeeping

Remedial Action to
achieve ALARP

L
Ref. No.

Hazard Description

Unstable material

Working at height

Relevant Activities

Source

shifting material from/onto

lifting of t-bar
conveyor
changing consumable,
maintenance works

machine gantry, magnetic

crane

Top Event

Threat

Consequence

RISK RANKING ACCORDING TO RAM

R
L
C
R
L
C
R

E (I)

Threat Barriers / Recovery Controls

competent operator, use of passageway for

material transfer, lifting height as low as possible
to ground level, PPE, daily inspection condition
for magnetic bar.

item drop

wrong method of lifting,

incompetent operator.

damage to material &

equipment, bodily injury,
fatality

2 C

1 A

1 B

fall

incomplete PPE

injury

2 A

1 A

1 C

1 hook safety belt whenever required

injury and equipment

damage

2 A

1 A

1 C

Barrier
Effectiveness

Risk

Effective

Effective

Effective

Effective

Partially Efctv.

Effective

Autopanel Welding Line

competent operator, use of passageway for
material transfer, lifting height as low as possible
to ground level, PPE, daily inspection condition
for transfer car and crane

Plate shifting

transferring plate from

cutting table to plate fit up transfer car and crane
machine

slip and fall

improper loading condition

Welding fumes

welding

SAW welding flux, welding slag

Expose to welding fumes

flux vacuum not properly suck air pollution for breathing

1 C

1 C

1 C

1 mask,

Hydraulic oil

machine functioning

mechanical components

slip and fall

leaking from hydraulic tubing

and cylinder also over
injury and look dirty
lubricant

2 D

2 D

2 D

2 cleaning for hydraulic leakage

Plate moving

up down roller for

moving plate

roller opening

caught between roller up and

fall

safety alert

1 A

1 C

1 A

1 allowed during operation

Hydraulic pusher

alignment and fit up

fit up machine

caught between parts

hydraulic failure, incompetent injury and material

operator
damage

2 C

1 A

1 A

Competent operator, follow machine operation

and working procedure

Effective

Heavy lifting

over turning plate

over turning crane

fall down

incompetent rigger, improper

material damage and
lifting gears and improper
fatality
lifting procedure

2 D

2 A

1 C

Competent riggers heavy lifting procedure, PTW,

and proper PPE

Partially Efctv.

Transferring steel
material

stiffener arrangement

magnetic crane

fall down

incompetent machine
material damage and
operator and machine failure injury

2 C

1 B

1 C

Competent riggers, lifting procedure and proper

PPE

Partially Efctv.

Conveyor moving

plate moving

chain conveyor

caught between parts and

damage

control and parts failure

material damage and

injury

2 A

1 A

1 C

1 Competent operator, alarm and proper PPE

Partially Efctv.

Intense light / ray

welding

arc

expose to intense light /arc

looking directly to intense light

without UV protection glasses,
wrong lenses

arc eyes (conjunctivitis)

2 A

1 A

1 A

1 cream, wash eyes after coming from welding area

Partially Efctv.

Hot slag, flying spatters

welding

welding

hot slag and spatters landing on

combustibles materials and/or
human body

inadequate PPE,
absence/insufficient of fire
blanket/tray, noncompliance to
PTW

fire, skin burn

1 D

1 C

1 C

1 blanket/tray, housekeeping, PTW for board of vessel

Effective

Effective

injury

provide proper ventilation, wear suitable approved

use correct size of drip tray and tubing, immediate

safety awareness and unauthorized person is not

wear ultraviolet light eye protection , use UV skin barrier

remove combustible material nearby, adequate PPE,
Fire fighting equipment available nearby, provide fire
and structure

changing consumable,
maintenance works

machine gantry, magnetic

crane

fall

incomplete PPE

injury

2 A

1 A

1 C

1 hook safety belt whenever required

Heat

welding

arc and heated weldment

expose to heat

working too long in enclosed

heated area

heat stroke, fire

2 C

1 C

1 C

1 take regular breaks, PTW

Partially Efctv.

Noise pollution

gauging activities

material and workpiece

expose to high noise

should be using ear plug

protection

hearing problem

1 D

2 C

1 C

1 wearing approved ear plug / ear muff

Effective

Gases

welding

pipe line

expose to fumes

check the pressure gauge

environmental pollution

1 D

2 C

1 C

Effective

Grease

maintenance and
servicing activities,
parts leaking

mechanical parts

slip and fall

poor housekeeping, spill

injury

2 C

1 D

2 B

regular cleaning of work place, placement of oil

1 containment , ensure availability of saw dust,
cloth/rags,

Partially Efctv.

Working at height

provide sufficient ventilation , drink plenty of water and

beware any pipe line leaking and always do the

preventive maintenance

Sub Assembly Line & Block Assembly Line

Gear oil

maintenance and
servicing activities, parts
leaking

gear box

oil spill

sudden splash of oil at initial

opening, improper tighten the
drain plug.

environmental pollution,
slippery floor

2 D

2 C

1 C

1 oil dispersant, use suitable gasket at drain plug,

Effective

Grease

maintenance and
servicing activities,
parts leaking

mechanical parts

slip and fall

poor housekeeping, spill

injury

2 C

1 C

1 C

regular cleaning of work place, placement of oil

1 containment , ensure availability of saw dust,
cloth/rags,

Partially Efctv.

contact with live part

leak current, poor earthing for

the welding machine, damaged
cable insulation, cables
submerged in water, safety
device failure.

inspect cables & equipment and connection visually

before energizing, periodic inspection for cables /
equipment / safety device, provide proper earthing to
1 ground, use of cable hanger to avoid cable submerged
in water and hit by vehicles, Ensure availability of Fire
watchmen and fire extinguisher, compliance to PTW,
segregate cables and gas hoses

Effective

Dropped items, Crane clash

wrong method of lifting,

undersize wire/lifting belt, faulty
lifting gears, incompetent rigging items damage, injury,
personnel, special lifting tool not fatality
properly installed, safety device
failure.

2 C

2 C

1 C

competent personnel (rigger, supervisor, crane

operator), quarterly inspection of lifting gears,
1 crane moving alarm, safety devices, avoid being
under suspended load, use of passageway for
material transfer,

Partially Efctv.

fall down from high place

improper PPE usage, working

over limited area,

items damage, injury,

fatality

1 C

1 C

1 C

hook safety belt whenever required, watch steps

and work at safe area,

Partially Efctv.

welding confined space,

inadequate ventilation

respiratory system problem,

metal fume fever

2 C

1 C

1 C

2 mask,

heat stroke, fire, skin

burning, equipment damage

1 C

1 C

2 C

1 take regular breaks, PTW

Effective

Effective

Partially Efctv.

High current

equipment Connection,
Welding activities,

SSB, Feeder Pillar, External DB,

Welding power source

Lifting items & Heavy

Lift.

block and equipment

installation

lifting transferring of blocks and

equipment

Working at height

welding and maintenance equipment failure, block

activities
assembling

electrocution, fire, fatality

2 C

1 C

1 C

immediate cleaning of spill, make available (standby) of

Welding fumes

welding

welding flux, shielding gas, coated

expose to welding fumes
metal surface,

provide continuous ventilation, wear suitable approved

Heat

welding

arc and heated weldment

workers and equipment expose to working too long in enclosed

heat
heated area, congested area,

Flammable item i.e.,

paint, thinner, gases

painting, gas center

gas pipeline, gas cylinder,

flammable items caught fire

storage of paints, hot work

activities e.g., cutting &
welding

fire

1 C

1 C

2 C

HV electrical hazard

cable access and

connection

high voltage

expose to live parts

visitors, unauthorized person

fire, fatality, flashover

2 B

2 C

1 C

2 perimeter, warning signs

provide sufficient ventilation , drink plenty of water and

Workshop Condition
fire extinguisher to be available, no hot work at
paint storage area/gas farm/gas pipeline
authorized person only, visitors log book, fenced

Remedial Action to
achieve ALARP

L
Ref. No.

Hazard Description

Abnormal posture in
long duration

Excessive moisture

Repetitive motion
Manual lifting

Relevant Activities

Source

construction activities

fabrication machineries

steel plate, electric

components

humidity from atmosphere

daily operations

construction area

moving light part

machine parts

Top Event

standding/sitting/squarting
during construction activities

Threat

working long hours

live parts expose to high humidity space heater malfunction

welding, grinding, gouging,

hammering, chipping
lifting of items/material

working long hours

incorrect lifting method

Consequence

RISK RANKING ACCORDING TO RAM

R
L
C
R
L
C
R

E (I)

Threat Barriers / Recovery Controls

restricted blood flow,

cumulative trauma
disorder (CTD), back
pains,

2 A

1 A

1 A

part damage

2 C

2 A

1 C

1 indicator (light and meter indicators) , monthly

1 A

1 A

1 A

damage to nervous
system
Back pain

Barrier
Effectiveness

Risk

Tool box meeting, Safety briefing

Effective

Partially Efctv.

Effective

Partially Efctv.

Partially Efctv.

Partially Efctv.

Daily / continuous visual monitoring of space heater

inspection by 3rd party

Tool box meeting, Safety briefing

Tool box meeting, Safety briefing

1 B

1 A

1 A

2 A

1 A

2 A

2 Wear safety shoes and proper PPE

2 D

2 D

2 B

1 prior to disposal, , use mouse trap and avoid rats

Slippery floor

daily operations

rain water, drainage

slip and fall

slippery floor from rain water ,

body injury
heavy rain, clogged drain

Pest (.g.; rats,

cockroaches, crow)

rubbish box

dirty place

Improper disposal creates pests

breeding area

improper disposal (unsealed

waste bags) of food waste

spread of food borne

diseases

Noise pollution

operations

fabrication machineries

expose to high noise

long exposure to noise

hearing impairment

2 C

1 C

1 C

1 wear hearing protection when entering generator house Effective

Congested working
space

plate arrangement and

storage

machines parts kept in workshop

(work in progress)

trips & fall

work in progress, dismantled

parts cannot be assembled
immediately due to waiting for
spare parts,

injury

1 C

1 C

1 C

2 housekeeping,

Partially Efctv.

Clogged and dirty drain

over flow water

drainage and raining

pest breeding

drain clogged by rubbish,

improper drainage system,

spread of disease, bad

odour

2 C

1 C

1 C

1 Food trap installed at each drain

Partially Efctv.

Ergonomic hazards

daily activities

machines parts

wrong lifting method, heavy

manual lifting/handling of
components, repetitive
back pain, muscle sore,
heavy components, repetitive
motion, lack of awareness on fatigue, sprain
motion e.g., grinding, polishing
ergonomic hazard

1 C

1 C

1 C

1 Training on ergonomic hazards, supervision

Effective

Assessors
Hamid bin Rabu (Production Manager)
Azhar bin Abd Jalil (QA Head)
Nor Azlan Helmi bin Mohd Yunos (Production & Facilities Exec.)
Ahmad Ezudin Shah bin Bakarrudin (Construction Exec.)
Zamani bin Ibrahim (HSE Exec., QHSE)
Khamisah Aspar (Head Quality, QHSE)

daily disposal from main rubbish bin, use of proper

plastic bags, ensure plastic bags are sealed properly
poison, daily cleaning of food preparation and storage
area

Keep clear of passageway, maintain good

Remedial Action to
achieve ALARP