Risk Assesment

List Of Deaprtments
Gate house and security office

HT room 1
Director's Office
Main Office
HT Room2
TR Room
LT Room
Comp Room
Regrind
QC Office
Manager's Office
Toilets
Injection Molding Shop
QC Lab
Die Shop
Store Office
Store
Maintenance workshop
Rim Packing
Nickle office
Oven 2
Oven 1
Electroplating shop
Electrolating shop rim
Packing
Fuel tank welding line
Rim Plant
Transformer Room
LT room
Polishing shop fender
Rim Polish shop
Oven 2
Canteen
Kitchen
Shearing Shop
Store Packing
Oil store
workshop
Scrap area
Weight Scale
OJ SPACE IDENTIFICATION
Offices and Security Electrical rooms

1 Gate House 1 HT Room1
2 Director's Office 2 HT Room2
3 Administration Office 3 Transformer room 1
4 QC Office 4 Transformer room 2
5 Store office 5 Compressor Room
6 Maintenance Office 6 LT room
7 Nickel shop office 7 Generators
Production Areas Services Areas
1 Injection Molding shop 1 Canteen
2 Rim Plant 2 Kitchen
3 Fuel Tank welding line 3 Toilets
4 Press shop Miscellaneous Areas
5 Shearing shop
6 Polishing shop fender 1 Open space
7 Rim Polishing shop 2 Garden area
8 Oven area 1 3 Car Parking
9 Oven area 2 4 Walkways(Indoor Outdoor)
10 Electroplating Shop
11 Rim Electroplating shop
Auxiliary Areas
1 Store office
2 QC Lab
3 Die Shop
4 Maintenance Workshop
5 Scrap area
6 Weight scale and Office
7 Oil store
8 Work shop
9 Regriding Area
Risk Assessment Sheet for Injection M
Area: Injection Molding
Rating Bands (L x S)
LOW RISK MEDIUM RISK HIGH RISK
(0 – 4) (5 - 10) (12 - 25)
Continue, but review STOP THE ACTIVITY

Continue, but implement additional reasonably practicable controls where Identify new controls. ACTIVITY must not
periodically to ensure
possible and monitor regularly proceed until risks are reduced to a low or
controls remain effective medium level
RISK
Problem Observation / Effect Counter Measure Required
L
Dangerously placed unorganised Inventory stack. Inventory stack reaching Stacking must be managed and placed in
1 Inventory stack up to 7 meter placed on walkways and unorganised can cause accidents designated place without any delay A
in case of fall
Molds stacking area floor setteled in a curve shape. Molds stacking is Molds stacking floor must be
extremely dangerous and done on a unleveled floor. This can cause reconstructed with required level of
2 Mold storage area A
misbalancing resulting in falling of molds which can be extremely compaction so that sagging of floor does
dangerous. not occur
Proper warning sign must be placed

During crane operation no warning signs are displayed. Lack of warning during crane operation any crossing path
3 Crane signs during crane operation can cause serious accidents .Lack of warning A
under crane must be closed during
signs during crane operation can cause serious accidents . operation
Page 3 of 89
(0 – 4) (5 - 10) (12 - 25)

RISK
L
No specific path provided for crane operater. Crane operator can trip or Specific path for crane operator must be
4 Crane Operator A
fall and crane can get out of control. provided.
oil spill should be eradicated as soon as

Oil spill on floor.Oil spill due to maintenance activity / machine problem
5 Slippery floor possible and leakages should be checked B
can cause slippage and accidents. and repaired
No warning signs. Lack of precautionary displays e.g electrical, falls, Precautionary signs should be placed
6 Warning signs tripping, slippery floor, walkway not clear can cause accidents in B
where any hazard is possible
ignorance.
No safety helmets. Absence of safety helmets can cause serious head

7 saftey helmets Safety helmets should be provided B
injuries.
Page 4 of 89
(0 – 4) (5 - 10) (12 - 25)

RISK
L
safety shoes must be provided and their

8 Safety shoes Absence of safety shoes can cause foot injury and slippage. E
use must be assured
PPE (Personal Protective Equipment). Absence of PPE can cause damage PPE must be provided and their use
9 PPE D
to different body functions like eyes damage, hearing loss, skin burns etc. must be assured
Page 5 of 89
(0 – 4) (5 - 10) (12 - 25)

RISK
L
Air coolers and proper ventilation must

High temperature can cause heat stroke and dehydration if exposed for be provided specially in summers.
10 Enviornment C
longer period of time can cause other health problems. Drinking water must be provided in
nearby location.
Hanging Electrical cables and unsafe electrical connections. Hanging Electrical cables should be conduited
11 Electrical cables electrical cables can cause serious accidents and can result in huge loss. properly and connection must be done 4
And unsafe electrical connections can damage equipment and cause fire safely.
Mold release spray can be inhaled accidently by the worker and can cause Face mask must be provided and their
12 Chemical hazard 2
health issues use must be assured
Page 6 of 89
(0 – 4) (5 - 10) (12 - 25)

RISK
L
Audited By:
Acknowledged By:
Page 7 of 89
ction Molding
Date: 9-May-18
L= likelihood
S= Severity
Risk(According to risk matrix)
RISK Responsible
OVERALL RISK Action Taken Hazard Removed
Person
S R
MEDIU
4 LOW
M
MEDIU
4 LOW
M
MEDIU
5 LOW
M
Page 8 of 89
ction Molding
Date: 9-May-18
L= likelihood
S= Severity
RISK Responsible
Person
S R
MEDIU
4 LOW
M
2 LOW LOW
MEDIU
3 LOW
M
MEDIU
4 LOW
M
Page 9 of 89
ction Molding
Date: 9-May-18
L= likelihood
S= Severity
RISK Responsible
Person
S R
3 HIGH LOW
1 LOW LOW
Page 10 of 89
ction Molding
Date: 9-May-18
L= likelihood
S= Severity
RISK Responsible
Person
S R
MEDIU
2 LOW
M
MEDIU
A LOW
M
B LOW LOW
Page 11 of 89
ction Molding
Date: 9-May-18
L= likelihood
S= Severity
RISK Responsible
Person
S R
Confirmed By:
Page 12 of 89
Risk Assessment Sheet for Rim Plant
Area: Rim Plant Date: 9-May-18
Rating Bands (L x S) L= likelihood

LOW RISK MEDIUM RISK HIGH RISK S= Severity
(0 – 4) (5 - 10) (12 - 25) Risk(According to risk matrix)
Continue, but STOP THE ACTIVITY

review periodically Continue, but implement additional reasonably practicable controls Identify new controls. ACTIVITY must
to ensure controls where possible and monitor regularly not proceed until risks are reduced to
remain effective a low or medium level
RISK Responsible Hazard

Problem Observation / Effect Counter Measure Required OVERALL RISK Action Taken
Person Removed
L S R
Walkway marking faded almost invisible. Because of this a safe walking Walkway should be marked properly
1 Walkway space is not ensured. Which can cause accidents. and should be kept clear. E 2 MEDIUM LOW
Equipment should be well taken care

Unattended Unattended equipment on floor can cause hindrance and damage to
2
equipment and tools quipment.
of. If not in use should be stored D 2 MEDIUM LOW
properly.
No guard on rim No guard on rim grinding wheel can cause accident in case of disc break. Rim grinding m/c must be provided
3 grinding Which can be extremely dangerous. with guard. B 3 MEDIUM LOW
Workers are not using PPE . Absence of PPE Like Safety helmets , safety PPE must be provided and their use
4 No PPE shoes, protective googles etc can increase intensity of accident. must be ensured. C 2 MEDIUM LOW
Trolleys on floor Trolleys on floor area can cause confusion on especially in an unwanted Trolleys must be placed at their
5
Area place can be cause of hinderence and blockage of walking area designated area and floor area must C 1 LOW LOW
be clean of any blockages
Air coolers without Desert air coolers are without guard can cause accident and worker health is Desert air coolers must be provided
6
guard at risk with fan gaurds
A 2 LOW LOW
unorganised
unorganised Inventory at but welding station can cause blockage of walking Inventory must be placed and stacked
7 inventory at butt
area and can increase intenstiy of any foul event if happens. properly.
A 3 LOW LOW
welding
Page 13 of 89



Person Removed
L S R
Absence of warning Warning signs for hazrds like eletrical, physical and chemical are not present. Proper displays for warning must be
8
signs Unidentified hazards can cause huge accidents in ignorance. provided.
A 3 LOW LOW
Page 14 of 89



Person Removed
L S R
Unattended open unattended open electrical cables can cause accidents. electrical cables should be placed
9
electrical cables properly on cable trays . Open end A 4 MEDIUM LOW
should be insulted properly
Loose connections must be attended

loose electrical Loose electrical connections can cause accidents . If touched by mistake can properly and proper sockets must be
10
connection cause accident.
A 4 MEDIUM LOW
provided
No sample board . Samples are placed at potentially dangerous place. If it Proper sample board must be
11 Sample board
falls can cause damage to equipment or process provided at a feasible place.
A 1 LOW LOW
Air storage tank in rim shop can develop cracks or blast . Which can be a Must be maintained properly. There
12 Air storage tank fatal event. should be preventive maintenance A 5 MEDIUM LOW
plan and it should be implemented.
13
14
15
Audited By: Confirmed By:
Page 15 of 89



Person Removed
L S R
Acknowledged By:
Page 16 of 89
Risk Assessment Sheet for Fuel Tank Production
Area: Fuel Tank Production Area Date: 10-Jan-20

Continue, but review

STOP THE ACTIVITY
periodically to ensure Continue, but implement additional reasonably practicable controls
Identify new controls. ACTIVITY must not proceed until risks are reduced
controls remain where possible and monitor regularly to a low or medium level
effective
RISK
OVERAL Responsible
Problem Observation / Effect Counter Measure Required L RISK Action Taken Person Hazard Removed
L S R
Walkway should be marked properly and should be kept clear.

Walkway marking faded almost invisible. Because of this a safe Manufacturing process must be considered before designing
walking space is not ensured. Which can cause accidents. Walkways MEDIU
1 No Walkway are not well designed no area designated for raw material stacking walkway layout. Walkway should be designed in way that it E 2
M LOW
and other movements. remains clear all the time. A minimum of 1 m walkway must be
provided.
Oil spills on draw press can cause slippage or other chemical hazards. Oil spills must be controlled. If from maintenance activity must be
2 Oil spills Can increase intensity of any foul event if happens. removed as early as possible.
B 2 LOW LOW
Raw material metal sheet for draw press placed on floor can cause There must be designated and marked place for placing raw
3 No designated place for injury to workers or other damage. This can increase intensity of any material sheets and these should be in a protective casing away B 3
MEDIU LOW
raw material foul event if happens. from walking area. M
No designated path for No designated path for trolley movement causing hindrance on A specific designated and marked path for trolley movement must
4 trolley movement. walking area which can cause accidents. be provided.
A 2 LOW LOW
Unattended tools or items on floor area can cause blockage for Tools or other items must be removed as early as possible after
unattended items on walking or other activity. Can increase intensity of any foul event if their use is over. A specific marked place must be designated for
5 floor area
A 2 LOW LOW
happens. their storage.
Workers wearing casual shoes and even slippers which can be

6 No safety shoes extremely dangerous specifically in sheet metal production area. Safety shoes must be provided and their use must be ensured. E 3 HIGH LOW
Page 17 of 89


STOP THE ACTIVITY
effective
RISK
OVERAL Responsible
L S R
unorganized inventory unorganized inventory on floor area can cause accident by itself and In process inventory stock must be placed in a designated marked
7 and carton stock also can increase intensity of any foul event if happens. area. Which should not block any walking area.
A 3 LOW LOW
Page 18 of 89


STOP THE ACTIVITY
effective
RISK
OVERAL Responsible
L S R
Absence of warning Warning signs for hazards like electrical, physical and chemical are not
8 signs present. Unidentified hazards can cause huge accidents in ignorance. Proper displays for warning must be provided.
A 3 LOW LOW
Foul electrical Electrical connection are found to tangled in to each other and Electrical connections must be done properly and should be made MEDIU
9 connection. temporarily placed. Which can cause electrical hazard and increase permanent where ever possible. Temporarily connections must be A 4
M LOW
intensity of any foul event if happens. made in proper way.
Conveyour belt hooks are dangours can easily cause accidents . Eyes Conveyor belts are required to marked with bright paint so that
10 Conveyour belt hooks and other face area are more exposed to danger. they are visible even from a distance. Hooks must be higher than 3 E HIGH LOW
human height.
11 No safety photo sensor Absecne of safety sensor on presses can cause serious injuries and
on presses accidents.
safety sensors must be installed and their consistency must be
confirmed periodically.
3 E HIGH LOW
Acknowledged By:
Page 19 of 89
Risk Assessment Sheet for Fender Press Shop
Area: Fender Press Shop Date: 9-May-18


review periodically Continue, but implement additional reasonably practicable controls Identify new controls. ACTIVITY
to ensure controls where possible and monitor regularly must not proceed until risks are
remain effective reduced to a low or medium level
RISK
Problem Observation / Effect Counter Measure Required OVERALL
Action Taken Responsible Hazard
RISK Person Removed
L S R
Walkway should be marked

properly and should be kept clear.
Walkway marking faded almost invisible. Because of this a safe walking Manufacturing process must be
space is not ensured. Which can cause accidents. Walkways are not well considered before designing
1 No Walkway designed no area designated for raw material stacking and other walkway layout. Walkway should E 2 MEDIUM LOW
movements. be designed in way that it remains
clear all the time. A minimum of 1
m walkway must be provided.
Unsorted and Draw Press draw parts inventory in placed at near walking area. These parts There should be designated place
2 dangerously placed contain sharp edges and can be extrememly dangerous can cause injury to for such kind of inventory which E 2 HIGH LOW
draw press inventory workers. should be enclosed .
There must be designated and

Raw material metal sheets for draw press placed on floor with any danger marked place for placing raw
3 Raw sheet metal indication or enclosed space can cause injury to workers or other damage. material sheets and these should E 2 HIGH LOW
This can increase intensity of any foul event if happens. be in a protective casing away
from walking area.
No designated path No designated path for trolley movement causing hindrance on walking area A specific designated and marked
4
for trolley movement. which can cause accidents. path for trolley movement must be A 2 LOW LOW
provided.
Page 20 of 89


RISK
RISK Person Removed
L S R
Tools or other items must be

removed as early as possible after
unattended items on Unattended tools or items on floor area can cause blockage for walking or
5
floor area other activity. Can increase intensity of any foul event if happens. their use is over. A specific marked A 2 LOW LOW
place must be designated for their
storage.
Page 21 of 89


RISK
RISK Person Removed
L S R
Workers wearing casual shoes and even slippers which can be extremely Safety shoes must be provided and
6 No safety shoes dangerous specifically in sheet metal production area. their use must be ensured. E 3 HIGH LOW
Absence of warning Warning signs for hazards like electrical, physical and chemical are not Proper displays for warning must
7
signs present. Unidentified hazards can cause huge accidents in ignorance. be provided.
A 3 LOW LOW
Electrical connections must be

Hanging wires and Electrical connection are found to tangled in to each other and temporarily done properly and should be
8 foul electrical placed. Which can cause electrical hazard and increase intensity of any foul made permanent where ever A 4 MEDIUM LOW
connections. event if happens. possible. Temporarily connections
must be made in proper way.
Oil spills must be controlled. If

Oil spills on draw press can cause slippage or other chemical hazards. Can
9 Oil spills
increase intensity of any foul event if happens. from maintenance activity must be B 2 LOW LOW
removed as early as possible.
Unattended and Unattended and mishandeled scrap material can cause accidents because Scrap material must be handeld
10 Mishandled scrap sheet metal scap has sharp edges which can also cause injuries can increase properly. Scrap bins provided must D 2 MEDIUM LOW
material intensity of any foul event if happens be used for wastage.
11 No reporting of FE use FE use not reported. Empty cylinder can cause confusion for during event of Use of FE must be reported as
of fire. early as possible A 3 LOW LOW
Page 22 of 89


RISK
RISK Person Removed
L S R
Must be maintained properly.

Air storage tank in fender press can develop cracks or blast . Which can be a There should be preventive
12 Air storage tank
fatal event. maintenance plan and it should be
A 5 MEDIUM LOW
implemented.
Presses should be maintained so

that unpredictible behaviours of
Presses are not well maintained and their behaviour is spmetimes machines can be avoided. A SOP
13 Equipment unpredictible. Procedure to mount and unmount dies is not safe. This can must formulated for mounting and D 3 HIGH LOW
cause accidents. Injury and asset loss can be the consequences. unmounting of dies. PPE must be
ensured before starting this
activity.
safety sensors must be installed

No safety photo Absecne of safety sensor on mechanical presses can cause serious injuries
14 sensor on presses and accidents. and their consistency must be 3 E HIGH LOW
confirmed periodically.
Acknowledged By:
Page 23 of 89
Risk Assessment Sheet for Die Shop
Area: Die Shop
(0 – 4) (5 - 10) (12 - 25)

Continue, but implement additional reasonably practicable controls Identify new controls. ACTIVITY
where possible and monitor regularly must not proceed until risks are
controls remain effective reduced to a low or medium level
RISK OVERAL
Problem Observation / Effect Counter Measure Required L RISK
L S R
Walkway should be marked

properly and should be kept clear.
Mainenance process must taken in MEDIU
Walkway not marked.There is no defined walking area. So a safe walking
1 No Walkway to consideration before designing E 2 LOW
area is not ensured. walkway layout.And proper M
warning sign must be dispalyed
when lifter is in operation.
Oil spills must be controlled. Any

Oil spill from surface grinding machine can be cause of slip and triiping. It
2 Oil spills can increase intensity of any foul event if happens. causes for oil spill must be B 2 LOW LOW
removed.
Area: Die Shop
(0 – 4) (5 - 10) (12 - 25)

RISK OVERAL
L S R
Tools or other items must be

removed as early as possible after MEDIU LOW
unattended tools items on Unattended tools or items on floor area can cause blockage for walking or
3 their use is over. A specific marked E 2
floor area other activity. Can increase intensity of any foul event if happens. place must be designated for their M
storage.
Workers wearing casual shoes which can be extremely dangerous specifically Safety shoes must be provided and
4 No safety shoes in die maintenance area.Any heavy part can fall on foot and cause injury. their use must be ensured. E 3 HIGH LOW
Area: Die Shop
(0 – 4) (5 - 10) (12 - 25)

RISK OVERAL
L S R
Absence of warning signs Warning signs for hazards like electrical, physical and chemical are not Proper displays for warning must
5 present. Unidentified hazards can cause huge accidents in ignorance. be provided. A 2 LOW LOW
Area: Die Shop
(0 – 4) (5 - 10) (12 - 25)

RISK OVERAL
L S R
Electrical connections must be

6 Loose electrical
Foul electrical connection. electrical hazard connectionsand damaged wiring for welding plant can cause done properly and should be A 4
MEDIU LOW
made permanent where ever M
possible.
7 No PPE No PPE present. Can cause injury or other accidents during machining and PPE must be porovided and their E 2
MEDIU LOW
other processes. use must be ensured. M
Area: Die Shop
(0 – 4) (5 - 10) (12 - 25)

RISK OVERAL
L S R
Acknowledged By:
Sheet for Die Shop
Date: 9-May-18
L= likelihood
S= Severity
Responsible Hazard
Action Taken Person Removed
Sheet for Die Shop
Date: 9-May-18
L= likelihood
S= Severity
Responsible Hazard
Sheet for Die Shop
Date: 9-May-18
L= likelihood
S= Severity
Responsible Hazard
Sheet for Die Shop
Date: 9-May-18
L= likelihood
S= Severity
Responsible Hazard
Sheet for Die Shop
Date: 9-May-18
L= likelihood
S= Severity
Responsible Hazard
L= likelihood
S= Severity
Risk Assessment Sheet for Shearing Shop
Area: Shearing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

Continue, but review periodically to ensure Continue, but implement additional reasonably practicable controls Identify new controls. ACTIVITY
controls remain effective where possible and monitor regularly must not proceed until risks are
reduced to a low or medium level
RISK

L S
Walk way must be marked and

No / faded walkway. No marking for storage and Faded or no walkway can cause confusion for walking area and storage storage areas must be sperated.
1 E 2
placing raw material sapce. This can cause accident in ignorance. Walkway must be kept clear all the
time.
There must be a designated and

Raw material sheets are placed without any warning sign and enclosed
2 Undesignated place for raw sheet material enclosed place for these kind of C 4
space. These sheet have sharp edges and can be cause of injury. materials.
Area: Shearing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
There is no fire extiguisher in shop and due to electrical supply fire hazard is CO2 fire extinghuisher must be
3 No fire Extinguisher in shop A 3
present. Fire control can be difficult if happens. provided.
Working wearing casual or slippers. Sheet have knife sharp edges. This can Safety shoes must be provided and
4 No safety Shoes E 3
cause svere injury in case of contact with edges. their use must be ensured.
Area: Shearing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
Hanging wire must be placed in

conduits and fixed properly.
5 Hanging electrical wires. Open electrical pannel. Hanging wires and open electrical pannel can be cause of electrical hazard. B 3
Keeping electrical panel open
open all the time must be avoided.
Audited By:
Area: Shearing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
Acknowledged By:
eet for Shearing Shop
Date: 9-May-18
L= likelihood
S= Severity
RISK
OVERALL Responsible Hazard
Action Taken
RISK Person Removed
R
MEDI LOW
UM
HIGH LOW
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
LOW LOW
HIGH LOW
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDI LOW
UM
Confirmed By:
L= likelihood
S= Severity
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R

Risk Assessment Sheet for Packing Shop
Area: Packing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S

No / faded walkway. No marking for storage and Faded or no walkway can cause confusion for walking area and storage storage areas must be sperated.
1 E 2
placing raw material sapce. This can cause accident in ignorance. Walkway must be kept clear all the
time.
There must be a designated and

Raw material sheets are placed without any warning sign and enclosed
2 Undesignated place for raw sheet material enclosed place for these kind of C 4
space. These sheet have sharp edges and can be cause of injury. materials.
Area: Packing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
There is no fire extiguisher in shop and due to electrical supply fire hazard is CO2 fire extinghuisher must be
3 No fire Extinguisher in shop A 3
present. Fire control can be difficult if happens. provided.
Working wearing casual or slippers. Sheet have knife sharp edges. This can Safety shoes must be provided and
4 No safety Shoes E 3
cause svere injury in case of contact with edges. their use must be ensured.
Area: Packing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
Hanging wire must be placed in

conduits and fixed properly.
5 Hanging electrical wires. Open electrical pannel. Hanging wires and open electrical pannel can be cause of electrical hazard. B 3
Keeping electrical panel open
open all the time must be avoided.
Audited By:
Area: Packing Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
Acknowledged By:
eet for Packing Shop
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDI LOW
UM
HIGH LOW
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
LOW LOW
HIGH LOW
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDI LOW
UM
Confirmed By:
L= likelihood
S= Severity
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R

Risk Assessment Sheet for Maintenance Sho
Area: Maintenance Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S

1
No / faded walkway. No marking for storage Faded or no walkway can cause confusion for walking area and storage storage areas must be sperated. E 2
and placing raw material sapce. This can cause accident in ignorance. Walkway must be kept clear all
the time.
This can cause foot injury. Due to nature of job feet are exposed to Safety shoes must be provided and
2 No safety shoes E 3
contionous danger. their use must be assured.
Loose electrical connection and foul wiring can cause electrical hazard. Skin electrical connections must be
3 Loose and foul electrical connections B 3
burn or electrical shock can be the cause if touched. made properly and
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Proper ventillation and fresh air

4 Hot and Humid Environment High tempurature can cause heat stroke. And long term health problems. B 2
intake must be provided.
Desert cooler fans must be

5 Ungaurded fans Ungaurded fans can accident . Can cause injury and asset loss. provided with grills to protect fans A 2
form direct contact.
Worker must be provided with

6 No hard hats Worker can get head injury and can be fatal in case of fall or head hit. hard hats and their use must be D 4
ensured.
Safety vest must be provided to

Woekers can get hit by equipment by human error if not seen by operator.
7 No safety vest safety workers and their use must A 4
Due to nature of job absence of safety vest can be cause of accidents. be assured.
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Safety belts must be provided to
Workers working on heights without safety belts or plateform. Also during
8 No safety belts woprkers and their use must be A 4
crane maintenance no ladder is used . assured.
Lathe machine must be provided
with hoists for large machining
Lathe machine activity is not secured can cause injury. This can be cause
9 Foul machining practices jobs and there must be proper B 3
injury to workers or damage to assest. partition during large machining
jobs.
Audited By:
Acknowledged By:
t for Maintenance Shop
Date: 9-May-18
L= likelihood
S= Severity
RISK OVERALL Responsible Hazard

Action Taken
RISK Person Removed
R
MEDIUM LOW
HIGH LOW
MEDIUM LOW
Date: 9-May-18
L= likelihood
S= Severity

Action Taken
RISK Person Removed
R
LOW LOW
LOW LOW
HIGH LOW
MEDIUM LOW
Date: 9-May-18
L= likelihood
S= Severity

Action Taken
RISK Person Removed
R
MEDIUM LOW
MEDIUM LOW
Confirmed By:
L= likelihood
S= Severity
Risk Assessment Sheet for Electroplating
Area: Electroplating
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S

1
No / faded walkway. No marking for storage Faded or no walkway can cause confusion for walking area and storage storage areas must be sperated. E 2
and placing raw material sapce. This can cause accident in ignorance. Walkway must be kept clear all
the time.
Safety shoes/long boots must be

This can cause foot injury. Due to nature of job and work environemnt
2 Sometime safety shoes/long boots are missing provided and their use must be E 3
slipage and chemical hazrad is present. assured.
Loose electrical connection and foul wiring can cause electrical hazard. Skin Electrical connections must be
3 Loose and foul electrical connections E 3
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
open electrical pannels can cause electrical hazard or fire if touched by Electrical pannels must be
4 Open electrical pannels E 3
mistake provided eith standard covering.
Circuit breakers are placed dangerously which can cause electrical hazard by Circuit breaker must be placed at
5 Dangeroulsy placed circuit breakers right position and with proper D 3
themselves. Electric fire or shock hazard is present. insulation.
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Work clothing must be full sleeves

no skin area must be
Chemical fumes can be dangerous can cause skin allergy, breathing exposed.Shower and emergency
6 CHEMICAL FUMES 2 E
problems, eyes burning etc. eye wash area must be provided.
Anti allergic medicines and
ointments must be provided.
Conveyour must be provided with

Low hanging parts from conveyour can cause hinderence during walking or warning signs and or must be
7 Conveyour belt above walking area is too low other movements. This can cause accident and damage to human health 1 E
raised to safe height above walking
and injury. areas.
exposed pulley drives can cause cause accidents clothes may stuck inside Pulley drive covers must be
8 No covers on bus bar drive pulleys 3 A
chain causing damage to human health and asset. provided.
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Loading/Unloading of raw materials done on walking area. This can cause Proper loading /unloading station
9 No loading/Unloading station for raw material 2 A
hinderence or may increase intensity of any acciedents if happens. must be provided.
10
11
Audited By:
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Acknowledged By:
eet for Electroplating
Date: 9-May-18
L= likelihood
S= Severity

Action Taken
RISK Person Removed
R
MEDIUM LOW
HIGH LOW
HIGH LOW
Date: 9-May-18
L= likelihood
S= Severity

Action Taken
RISK Person Removed
R
MEDIUM LOW
HIGH LOW
Date: 9-May-18
L= likelihood
S= Severity

Action Taken
RISK Person Removed
R
MEDIUM LOW
LOW LOW
LOW LOW
Date: 9-May-18
L= likelihood
S= Severity

Action Taken
RISK Person Removed
R
LOW LOW
Confirmed By:
L= likelihood
Date: 9-May-18
L= likelihood
S= Severity

Action Taken
RISK Person Removed
R
S= Severity
Risk Assessment Sheet for Polish Shop
Area: Polish Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S

1
No / faded walkway. No marking for storage Faded or no walkway can cause confusion for walking area and storage storage areas must be E 2
and placing raw material space. This can cause accident in ignorance. separated. Walkway must be
kept clear all the time.
This can cause foot injury. Safety shoes/long boots must be

2 Safety shoes missing Due to nature of job and sharp edges of parts feet are more exposed to provided and their use must be E 3
danger. assured.
Loose electrical connection and foul wiring can cause electrical hazard. Skin Electrical connections must be
3 Loose and foul electrical connections E 2
Area: Polish Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
Open electrical panels can cause electrical hazard or fire if touched by Electrical panels must be provided
4 Open electrical panels E 2
mistake with standard covering.
Provisions must made to improve

air quality.
Respirators must be used if air
Emery and Polish dust due to polishing activity quality is compromised.
Polish dust can cause respiratory track problems.
5 Emery and Polish dust Proper work clothing must be to D 3
Polish dust can cause skin allergies. avoid any skin exposure to dust.
Polish dust can cause irritation in eyes hence causing eye infection. Goggles must be used to avoid
dust/particles going in to eyes.
Area: Polish Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
Polishing procedure includes resting a corrugated carton on lap. Fire proof cushion must be
Due to grinding sparks carton can catch fire and is an extremely dangerous provided to avoid and fire incident.
activity.
6 Polishing procedure Emery belts quality must be 3 E
Emery belts runs at higher RPM. It often breaks which can cause injury to improved to reduce frequency of
workers and passer by. belt break.
Exposed pulley drives can cause cause accidents clothes may stuck inside Pulley drives must be provided
7 Exposed pulley drives 2 B
pulley causing damage to human health and asset. with proper covers.
There is no hazard indication which can cause accidents in ignorance or may Prominent hazard indication must
9 No hazard signs 4 B
increase intensity of any accident if happens. be provided.
Area: Polish Shop
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK

L S
A safe storage place must be

Hazardous materials placed on floor without any Hazardous material placed on floor like flammable liquids can cause fire provided for such materials and
10 3 B
precaution. hazards and can increase intensity of accident if happens. must not be left unattended for
long.
11
Audited By:
Acknowledged By:
heet for Polish Shop
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDIUM LOW
HIGH LOW
MEDIUM LOW
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDIUM LOW
HIGH LOW
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
HIGH LOW
LOW LOW
MEDIUM LOW
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDIUM LOW
Confirmed By:
L= likelihood
S= Severity
Risk Assessment Sheet for Main Store
Area: Main Store
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S

storage areas must be
1 No walkway defined No walkway is defined in store. E 2
separated. Walkway must be
kept clear all the time.
Worker has to climb an aisle to reach racks on height so this increases

2 No stairs for reaching high aisles Stairs must be provided. C 3
chance of fall hence causing injury.
Oil gallons can cause spillage of oil. Can increase intensity of any accident if Oil gallons must be stored properly
3 Oil gallons are stacked on each other C 1
happens. in racks.
Area: Main Store
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
most of the material in store is combustible like paper, wood, fabric etc. fire Properly rated fire extinguishers
4 No fire extinguisher in store hazard is present. Also absence of fire extinguisher can increase intensity of must be provided. D 3
any foul event if happens.
Dangerous materials and chemical

Hazardous materials are not stored separately and no hazard indication is must be stored separately and
5 Hazardous materials and chemicals. 2 B
present. hazard indication must be placed
prominently.
Audited By:
Area: Main Store
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Acknowledged By:
heet for Main Store
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDIUM LOW
MEDIUM LOW
LOW LOW
heet for Main Store
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
HIGH LOW
LOW LOW
Confirmed By:
heet for Main Store
Date: 9-May-18
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
L= likelihood
S= Severity
Risk Assessment Sheet for Crushing Area
Area: Crushing Area
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
No walkway is defined in crushing area. This can cause accidents Walk way must be defined and
1 No walkway defined E 2
because storage area is covering walking area. kept clear all the time
warning signs must be diplayed

2 No Hazard indication No warning signs are present which can cause accidents in ignorance. C 3
prominently.
Area: Crushing Area
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Loud noise can cause hearing problems. If exposure is for long period of Ear buds must be provided to
3 Loud noise time can damage hearing permanently minimise hazards. C 3
Due to nature of raw material fire hazard is present . This can increase Properly rated fire extinguishers
4 No fire extinguisher in crushing D 3
intensity of any foul event if happens. must be provided.
Area: Crushing Area
(0 – 4) (5 - 10) (12 - 25)
STOP THE ACTIVITY

RISK
L S
Audited By:
Acknowledged By:
eet for Crushing Area
Date: ###
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDIUM LOW
MEDIUM LOW
Date: ###
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
MEDIUM LOW
HIGH LOW
Date: ###
L= likelihood
S= Severity
RISK
Action Taken
RISK Person Removed
R
Confirmed By:
Risk Assessment Sheet for Kitchen And Cooking
Area: Kitchen and Cooking Date: 9-May-18

STOP THE ACTIVITY

RISK
Problem Observation / Effect Counter Measure Required Action Taken
RISK Person Removed
L S R
No walkway is defined in crushing area. This can cause accidents Walk way must be defined and
1 No walkway 4 2 8 4
because storage area is covering walking area. kept clear all the time
warning signs must be displayed

2 No Hazard indication Absence of warning signs can cause accidents in ignorance.
prominently.
2 3 6 2
3 No Proper platform for cutting No platform for cutting this can cause back strain and other health problems. Ear buds must be provided to
minimize hazards. 1 3 3 1
Unhygienic washing area can cause disease spread and other health Proper washing area separate for
4 No proper vegetable & meat washing area problems.
veg and non-veg must be 1 3 3 1
provided.
No Fire suppression system in Kitchen hood Kitchen hood exhaust is more prone to fire hazard. Can cause to intensify fire Kitchen hood exhaust must be
5 exhaust hazard. provided with fire suppression 1 1 1 0
system.
LPG cut off valve must be placed at

LPG cut off valve is placed at a place which is not easy accessible in case of a prominent accessible point and
6 Inaccessible LPG cylinder cut off valve mishap and can be difficult to reach in case of a foul event. This can intensify with prominent instructions.(It is 5 1 5 1
any foul event if happens. far better to install a automatic
cutoff valve.)
Absence of fire suppression system can increase intensity of accident to an LPG cylinders must be provided
7 No fire suppression system above LPG cylinder extreme extent. with automatic fire suppression 1 5 5 1
system.
Page 86 of 89
Risk Assessment Sheet for Kitchen And Cooking

STOP THE ACTIVITY

RISK
RISK Person Removed
L S R
Acknowledged By:
Page 87 of 89
Risk Assessment Sheet For Weight Scale and Computer Room

Continue, but implement additional STOP THE ACTIVITY

Continue, but review periodically to ensure Identify new controls. ACTIVITY
reasonably practicable controls where must not proceed until risks are
controls remain effective
possible and monitor regularly reduced to a low or medium level

RISK Person Removed
L S R
No walkway is defined in crushing area. This Walk way must be defined and
1 No walkway can cause accidents because storage area is kept clear all the time 4 2 8 4
covering walking area.
Absence of warning signs can cause accidents warning signs must be displayed
2 No Hazard indication
in ignorance. prominently.
2 3 6 2
3 1 3 3 1
4 1 3 3 1
5 1 1 1 0
6 5 1 5 1
7 1 5 5 1
Risk Assessment Sheet For Weight Scale and Computer Room

Continue, but implement additional STOP THE ACTIVITY

Continue, but review periodically to ensure Identify new controls. ACTIVITY
reasonably practicable controls where must not proceed until risks are
controls remain effective
possible and monitor regularly reduced to a low or medium level

RISK Person Removed
L S R
Acknowledged By:

Risk Assesment

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List Of Deaprtments

Gate house and security office

Offices and Security Electrical rooms

Continue, but review STOP THE ACTIVITY

Proper warning sign must be placed

Continue, but review STOP THE ACTIVITY

oil spill should be eradicated as soon as

No safety helmets. Absence of safety helmets can cause serious head

Continue, but review STOP THE ACTIVITY

safety shoes must be provided and their

Continue, but review STOP THE ACTIVITY

Air coolers and proper ventilation must

Continue, but review STOP THE ACTIVITY

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

RISK Responsible Hazard

Equipment should be well taken care

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

RISK Responsible Hazard

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

RISK Responsible Hazard

Loose connections must be attended

Audited By: Confirmed By:

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

RISK Responsible Hazard

Rating Bands (L x S) L= likelihood

Continue, but review

Walkway should be marked properly and should be kept clear.

Workers wearing casual shoes and even slippers which can be

Rating Bands (L x S) L= likelihood

Continue, but review

Rating Bands (L x S) L= likelihood

Continue, but review

Audited By: Confirmed By:

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

Walkway should be marked

There must be designated and

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

Tools or other items must be

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

Electrical connections must be

Oil spills must be controlled. If

Rating Bands (L x S) L= likelihood

Continue, but STOP THE ACTIVITY

Must be maintained properly.

Presses should be maintained so

safety sensors must be installed

Audited By: Confirmed By:

Continue, but review STOP THE ACTIVITY

Walkway should be marked

Oil spills must be controlled. Any

Continue, but review STOP THE ACTIVITY

Tools or other items must be

Continue, but review STOP THE ACTIVITY

Continue, but review STOP THE ACTIVITY

Electrical connections must be

Continue, but review STOP THE ACTIVITY

Audited By: Confirmed By: