Guide 2001

RiSk maNaGemeNt at WoRk

WorkCover. Watching out for you. New South Wales Government

WorkCover NSW Health and Safety Guide

DisclaimerThis publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the

various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation.

Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au) or by contacting the free hotline

service on 02 9321 3333.

This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for

legal advice. You should seek independent legal advice if you need assistance on the application of the law to your situation.

© WorkCover NSW

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Contents • Howtousethisinformation�������������������������������������������������� 2

• Whatdothesymbolsusedinthisbookletmean?�������������������� 2

• RiskManagementatWork���������������������������������������������������� 3

• TheRiskManagementProcess���������������������������������������������� 4

Step1:HazardIdentification–Howdoyoudecidewhatisahazard?���������������������� 5

Step2:RiskAssessment–Howdoyoudeterminewhatharmtheycancause?��� 6

Step3:RiskEliminationandControl–Howdoyoudecidethebestwaytoremove

orreducetherisk?������������������������������������������������ 6

• WhendoyoudoRiskManagement?�������������������������������������� 7

• WhoshouldbeinvolvedinRiskManagement?������������������������ 8

• ThesixstepsinvolvedincreatinganOHSManagementSystem������������������������������������������������������������ 8

Step1:Determinewhoisresponsibleforhealthandsafety����������������������������������������������������� 9

Step2:Plantoworksafely������������������������������������������������� 10

Step3:Involveemployeesintheprocess����������������������������� 10

Step4:Developprocedures������������������������������������������������ 10

Step5:Trainpeopleintheprocedures�������������������������������� 11

Step6:Monitor,reviewandimprovethesystem������������������� 11

• WhatifSomethingDoesGoWrong?������������������������������������� 12

• Conclusion������������������������������������������������������������������������ 13

Example1–JobDesign����������������������������������������������������� 14

Example2–SafeWorkProceduresandTraining������������������ 18

Example3–PurchasingDecisions�������������������������������������� 20

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How to use this information

• What is this booklet all about? TheNSWOccupationalHealthandSafetyAct2000,in

conjunctionwiththeconsolidationofallassociatedregulationsintotheOccupational Health and Safety Regulation 2001,isthemostsignificantreformtooccupationalhealthandsafetylawsinalmost20years�

Thechangesintroduceamoveawayfromold-stylelawswhichattemptedtodetailhowhazardsweretobecontrolledineverysituation,toapositionwhichrequiresemployerstoassesstherisksposedbyhazardsintheirworkplaceandtodeterminehowbesttomodifytheirworkprocessestoeffectivelyeliminateorcontroltherisks�

Thisprocessisknownasrisk managementandisthemainfocusofthisguidancematerial�

• Who is this booklet for? Thisguidancematerialprovidesamodelforthesystematic

managementofworkplacehazardsthatcanbeusedby:ownersormanagersofsmallormediumsizedcompanies;OHSCommittees;OHSRepresentatives;oranyonewantingtoimproveworkplacehealthandsafety�

Itdemonstratesinapracticalwayjustwhatriskmanagementis,andhowemployersandemployeescanworktogethertomaketheirworkplaceandworkpracticessafeandefficient�

• When to use this information Aspartofreplacingoutdatedlawsandre-shapingthelegal

frameworktosuitmodernindustrialconditionsandworkpractices,thenewOHSActandtheOHSRegulationformallyintroduceriskmanagementintotheNSWregulatoryframeworkandmakeitmandatoryforemployerstoconsultwithworkersonmatterswhichaffecttheirhealthandsafety�

Understandingtheselegalrequirementsisanessentialpartofunderstandingtheroleofriskmanagementinthemanagementofworkplacehealthandsafetyandinknowingexactlyhowtomeetyourriskmanagementobligations�

Assess the risks in your workplace

Consult and communicate with employees

Tools that can help you work out your plan

Legal obligations that you must follow

Questions you (or others) might ask to clarify issues

The process of finding things that cause harm, working out how big a problem they are and then fixing them

What do the symbols used in this booklet mean?

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Becauseriskmanagementisapracticalwayoffindingandfixingworkplacehealthandsafetyproblemsitisbestillustratedbywayofaworkplaceexample�Considerthefollowingworkplaceexample:

Everyweek,twocouncilworkersarerequiredtocleanthepublictoiletblocksinthelocalparks�

Todothistheytakeatruckfromthedepot,whichhasasmallpressurepumpandhosestoredonthebackofit�Theydrivethetruckthroughthepark,uptothefrontofthetoiletblock,liftthepumpoffthetruck,carryitintothetoilets,attachthehosetothetapandcleantheblockwithhighpressurewater�

Whentheyhavefinishedhosingoutthetoilets,theycarrythepumpouttothetruckandreloaditontothebackofthetruckandgotothenextparkwithatoiletblock�

Asyoumightimagine,theydon’tlikedoingthisjob�Thepumpisheavyandawkwardtoliftandtheyfindthemselvesstrainingeverytimetheyhavetoliftitonandoffthetruck�Whentheyareusingthehoseintheconfinedspaceofthetoiletblockthenoiseissolouditcausesringingintheirearswhichcanlastforhours�Theyhavebeengivenearplugstowearbuttheyoftenforgettobringthemwhentheysetoutfortheday�

Sittinginthelunchshedonedaytheycomplaintotheforemanthattheyarenotgettinganyyoungerandtheyareworriedabout“doingtheirbacksin”liftingthepumpandthatthenoiseinthetoiletblockissendingthemdeaf�

Pete,themaintenancefitter,whoishavinghislunchintheshedoverhearstheconversationandbuttsinsaying,

“You’re bloody mad doing the job the way you do, I know how to make it much easier. Bring the truck to the maintenance yard tomorrow and I’ll fit a 30 metre hose which will reach from the truck inside the toilet block and then you won’t have to lift the pump off the truck in the first place”.

“What a great idea”, saysoneofthetwocleaners�“That will also make it much less noisy when we are in the toilet blocks with the hoses ’cause we’ll leave the noise outside”.

“You know Pete, you’re a bloody genius”.

Whatyouhavejustwitnessedintheexampleaboveistheriskmanagementprocessatwork�Betweenthem,Peteandthetwocleanershaveunknowinglyworkedthroughthestepsinvolvedinriskmanagementandasaresulthavesolvedtheproblemoftheheavy,noisypump�

Let’stakeacloserlookattheprocesstheywentthroughtodothis�

Firstly,thecleanersidentifiedthatthepumphadthepotentialtocausethemharmbecauseitwasheavytoliftandnoisy�Theythereforefoundthatthewaytheyweredoingthejobwashazardousandtheyknewthisbecausetheydidthejobregularly�Thehazards theyidentifiedwere:• ManualHandling

• Noise

Risk Management at Work

Step 1. Hazard Identification

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Step 2. Risk Assessment

Step 3. Risk Elimination or Control

The Risk Management Process

Becausethecleanershaveworkmateswhohavehurttheirbackliftingheavyobjectsandotherswhoarepartiallydeaffromworkinginnoisyenvironments,theyrealisedthattheytoowereatriskofsuchinjuries,particularlyastheycleanedthetoiletblockseveryweek�Therisksthattheywereconcernedaboutwhichresultfromthesetwohazardswere:

Hazards (Problem) Risks (Harm)

ManualHandling Musclestrain Backinjuries

Noise Hearingloss

TheywereluckythatPeteoverheardtheirconversationwiththeforemanbecausePetecameupwithagreatsolutiontoeliminatetheneedtoliftthepumpoffthetruckand,asthecleanerspointedout,italsosolvedthenoiseproblem�

Hazards (Problem) Risks (Harm) Control (Solution)

ManualHandling Musclestrain Changeworkpracticesby Backinjuries increasinglengthofhoseto eliminatetheneedtoliftpump

Noise Hearingloss Changeworkpracticesby increasinglengthofhoseto reducethenoiselevelinside thetoiletblock

Soyoucanseethat:byexaminingwhattheyhadtodoandwhatharmtheymightexperienceiftheykeptdoingthingsthesameway;andbytalkingtoothersabouttheirconcerns;thecleaners,withPete’shelp,havebeenabletosolvetheirprobleminaverypracticalway�Thisiswhatriskmanagementisallabout�

InOHSterms,riskmanagementistheprocessofrecognisingsituationswhichhavethepotentialtocauseharmtopeopleorproperty,anddoingsomethingtopreventthehazardoussituationoccurringorthepersonbeingharmed�Thisiswhatthecleanersdidintheexamplewehavejustlookedat�

Therisk management processconsistsofwell-definedsteps,whichcanbelikenedtotheproblem-solvingprocess,thatwhentakeninsequenceleadtoinformeddecisionsabouthowbesttoavoidorcontroltheimpactoftheserisks�Justliketheproblem-solvingprocess,riskmanagementinvolves:

Step 1:Identifyingtheproblem,whichisknownashazard identification�

Step 2:Determininghowseriousaproblemitis,knownasrisk assessment�

Step 3:Decidingwhatneedstobedonetosolvetheproblem, risk elimination or control�

Risk managementis the process of identifying and managing risks to avoid exposure or loss.

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Step 1: Hazard Identification - How do you decide what is a hazard?

Let’snowtakealookatwhatisinvolvedineachofthesesteps�

Employersmustmakesurethattheirworkplacesarefreefromhazardsthatcouldcauseinjuryordiseasetotheiremployeesortootherpersonsintheworkplace,suchascustomersorvisitors�Anemployer,inconsultationwithhisorheremployees,mustidentifyallpotentialhazardoussituationswhichcouldresultinanypersonintheworkplacebeingharmed�Theideaisthathazardsarefoundandsomethingisdoneaboutthembeforetheyactuallycauseanyharm�Howcanthisbedone?

Thepurposeofthehazardidentificationistofindallthehazardsbyaskingyourselfquestionsthatbeginwith“What if … ?”

Identifyingthehazardisonlythefirstpartofthisstep�Itisessentialthatyouobserveorpredictwhatcouldgowrongwhilethetaskisbeingperformed�

Therefore,thehazardidentificationprocessmustlookatthewholesystemofworkandrequiresyouto:

1� Takealookbackintothepastatwhataccidentshavealreadyhappened�

2� Talktotheworkersdoingthejobstofindoutwhattheyconsideraresafetyissues�

3� Takeawalkaroundtheworkareatoseeandhearwhatishappeningnow�

4� Reviewanyinformationyoumayhaveonaparticularpieceofequipment(manufacturersmanual)orchemicalMaterialSafetyDataSheets(MSDS)toseewhatitsaysaboutsafetyprecautions�

5� Thinkcreativelyintothefutureaboutwhatcouldhappenifsomethingwentwrong�Mostincidentsoccurwhensomethingdoesgowrong�

Walkingaroundaworksite,talkingwiththeworkersandobservinghowthingsareactuallydonewillhelpyoupredictwhatcouldormightgowrong�Observe:howpeopleactuallywork;howplantandequipmentisused;whatchemicalsarearoundandwhattheyareusedfor;whatsafeorunsafeworkpracticesexist;aswellas,thestateofthegeneralhousekeeping�

LookingbackoveranyOHSrecordssuchasaccidentrecords,nearmissrecords,workplaceinspectionreportsorworkerscompensationrecordswillalsogiveyoucluesastowhathazardsexist�The“describewhathappened”sectionofsuchreportswillhelpleadyoutotheproblem�Ifsomeonehasbeenhurtdoingaparticulartaskthenahazardexists,whichcouldhurtsomebodyelse�Othertimesthathazardsshouldbeidentifiedare:

• afteranearmissincident;

• afteranactualinjury�

Boththesesituationsrequireinvestigationtofindthehazardanditscause�

Step 2: Risk Assessment - How do you determine what harm they can cause?

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Onceahazardhasbeenidentified,anemployerisrequired,inconsultationwithhisorheremployees,todeterminehowlikelyitisthatsomeonecouldbeharmedbythehazardandhowserioustheinjuryorillnesscouldbe�

Thisisdonebyreviewinganyavailableinformationaboutthehazard�Thetypeofinformationthatyouwillneedtoexaminewillvarywiththetypeofhazardbutwillgenerallyincludesomeorallofthefollowing:

• Hazard informationwhichisrequiredtobesuppliedtoyouwiththeproductorequipmentsuchasMSDSormanufacturersinformation�

• Experience from the workplacewiththehazardorsimilarriskssuchasemployeesexperienceaswellasinjuryorincidentdata�

• ControlmeasuresprescribedinChapters4-8oftheOHSRegulation 2001,whichidentifiestheriskforparticularhazardsandminimumcontrolmeasuresforcertainknownhazards�

• WorkCover guidance materialwhichwillhelpyouassesspotentialrisksforparticularhazards,processesorworktasks�

• Industry Codes of Practicewhichwillgiveyoudirectionanddetailedguidanceontheidentificationandcontrolofhazardsinlinewithacceptedlegislativerequirementsandindustrystandards�

• Australian Standardswhichsetoutspecificationsforarangeofequipment,productsandmaterialstoensurethattheyaresafeandofagoodquality�AustralianStandardsrepresentgoodengineeringpracticeinrelationtofabricationanddesign�YoumustcomplywiththeonesthatarereferredtointheOHSRegulation�

Thethingtorememberis,iftheproblemisobviousandtheriskofinjuryishigh,acttocontroltheriskimmediatelyinsomeway,asaninterimmeasure�Thendotheresearchrequiredtoassesstheriskanddecideonthecontroloptions�Partoftheriskassessmentinvolvesidentifyingwhatyouneedtodotoeliminateorminimisetheriskanddecidingwhichcontroloptionisappropriategiventhedegreeofrisk�

Havingfoundthathazardsdoexistandthatpeopleareatriskofinjuryorillnessfromthem,thereisalegalcompulsiononemployerstodosomethingaboutthem�

Employersarerequiredtoremoveorfixanyhazardsor,ifthisisnot“reasonablypracticable”,theymustlessentheriskofharmtothelowestpossiblelevel�Ifwethinkbacktotheexampleofthetwocouncilworkerswecanseehowthisworks�

ThesolutionproposedbyPeteeliminatedthemanualhandlingriskaltogetherasitremovedtheneedforthepumptobemovedfromthetruckatall�Italsosignificantlyreducedthenoiseproblem�Clearlythisisthebestsolution�

Step 3: Risk Elimination or Control - How do you decide the best way to remove or reduce the risk?

When do you do Risk Management?

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Ifitwasnotpossibletofitalongerhosetothepump,forinstance,becausethepumpwasmanufacturedinsuchawaythatalongerhosewouldsignificantlydecreasetheeffectivenessofthepump,thenanothersolutionwouldbetoputappropriatewheelsonthepumpandfitaliftingdevicetothetrayorthetruck�Thiswouldallowthepumptobeloweredmechanicallytothegroundandthenwheeledintothetoiletblock�Itwouldnotreducethenoiseproblemandthiswouldstillhavetobefixed�

Ifitwasnotpossibleforthecounciltofitaliftingdevicetothetruckthenperhapsthetruckcouldbesuppliedwithrampstosuitthewidthofthepump�Thepumpcouldthenbewheeledonandoffthetruck�Whilethisdoesnotremovethemanualhandlingrisks,itreducesthemsignificantly�

Again,controllingrisksforcertainhazardswillrequireemployerstocomplywiththespecificcontrolssetoutintheOHSRegulation�

TheOHSRegulationspecificallystatesthatrisksmustbeminimisedbymeansotherthantheprovisionofpersonalprotectiveequipment(PPE)whereverpossible�PPEshouldonlybereliedonwhenthereisnoothersolutionandinmostinstancesshouldbeusedasasupplementtoothercontrolmeasures�

Riskmanagementisnotsomethingthatcanjustbefittedinwhenanemployerhastimeortheworkplaceisalittlequiet�OHSlawsrequirethathazardsareidentifiedandthatproceduresareinplaceandareusedtoidentify,assessandcontrolhazards:

• beforesettingupandusingaworkplace;

• whenplanningworkprocesses;

• beforeinstalling,commissioningorerectingplant;

• wheneverchangesaremadeto:

–theworkplace;

–thesystemormethodofwork;

–theplantused;

–thechemicalsused;

• whenevernewinformationregardingworkprocessesbecomesavailable�

How can this be achieved?Tomeettherequirementslistedabove,youneedtothinkabouthealthandsafetywheneverdecisionsarebeingmadeabouthowtheworkistobedoneandwheneverplansarebeingmadetoimproveproductivityorreducecosts�

Risksaremosteffectivelyidentifiedwhenworkactivitiesareactuallybeingdesigned,planned,talkedaboutanddecisionsabouttheimpactonhealthandsafetycanbemadeuncompromisingly�

Thismeansriskmanagementmustbe:planned;systematic;doneattherighttime;andcomprehensive,tocoverallpotentialhazardsandrisks�

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Who should be involved in Risk Management?

Theearlierexampleofthecouncilworkersshowedhowthoseaffectedbydecisionsabouthealthandsafetyarebestpositionedtohelpmakethejobsafer�Thetwoworkerswereabletoidentifytheproblembecausetheydidthejobregularly�Pete,themaintenancefitter,wasabletocomeupwiththesolutionbecauseheknewtheequipmentandhadthetechnicalskillstofindabetterwaytodothejob�

Consultationisacentralfeatureofriskmanagementbecauseinvolvingthepeoplewhodotheworkinidentifyinghazardsanddecidinghowtocontrolrisksisthemosteffectivewaytomanageworkplacehealthandsafety�

Thesepeopleknowthejob,knowwhatisneededtomakethejobsafe,knowtheproductionprocess,andaboveallknowhowbesttosolveproblemssothathazardsareeliminatedorcontrolled�

Consultationisrequired:

• wheneverriskstohealthandsafetyarebeingexaminedorreviewed;

• whendecisionsarebeingmadeaboutmeasurestakentoeliminateorcontrolrisks;

• whenintroducingoralteringanyproceduresforidentifyingandmonitoringworkplacerisks;

• wheneverchangesthatmayaffecthealthandsafetyareproposedtotheworkplace,thesystemofwork,ortheplantandsubstancesusedforwork;

• wheneverdecisionsaremadeaboutconsultationarrangements�

Inotherwords,consultationwithemployeesisrequiredwhenplanninghowworkistobedoneandbeforeworkinvolvinganynewprocesses,equipmentorchemicalsbegins�

Employersneedaprocessinplacetomakesurethatpotentialhazardsandthehealthandsafetyofpeopleintheworkplaceisnotoverlookedduringtheplanningofworkactivities�Thiscanonlybeachievedbyhavingpoliciesandproceduresinplace,whichmakeitimpossibletooverlookOHSintheoverallplanningoftheproductionprocess�

Thesystematicmanagementofworkplacehealthandsafetymeansmanagingworkactivitiestominimiserisks�An occupational health and safety management systemissimplyadocumented,co-ordinatedplantomakesurethehazardsandassociatedrisksaremanaged�

Forriskmanagementtobetrulyeffectiveitmustsurroundworkactivities�Itcannotbesimplyhazard-based,whereeffortsgenerallyattempttoputoutthe“bushfire”withoutmanagingtheworkactivityandtheenvironmentsafetyasawhole�

The OHS Act 2000 requires employers to consult with employees and take into account their views when making decisions that affect their health, safety and welfare. Involving your employees in identifying hazards and solving health and safety problems is an essential step in making your workplace safe and healthy.

The six steps involved in creating an OHS Management System

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Step 1: Determine who is responsible for health and safety

Whilethemainresponsibilityformakingsurethatworkactivitiesaresafelieswiththeemployer/ownerofacompany,thereisageneralexpectationthatemployeesworksafelyandtakecareinwhattheydosoasnottoputthemselvesorothersatrisk�

Theexpectationsofemployeescanbebrokendownintosuchthingsasbeingexpectedto:

• followprocedures;

• wearpersonalprotectiveequipment(PPE);

• reportanysafetyproblems;and

• reportincidentsandinjuries�

Inordertodothesethings,employeesneedtohaveprocedurestofollow,PPEtowearandameansofreportingOHSproblemsandinjuries�Therefore,acompanyneedstodeterminewhoisresponsiblefor:developingtheproceduresandthereportingmechanism;andpurchasingandsupplyingPPE�

Inmostworkplacesmanagersareusuallyresponsiblefortherangeofdecisionsaboutwhatthecompanywilldoandhowitwillbedone�Decisionssuchaswhatproductsandservicesthecompanywillproduce,howthiswillbedoneandwhowilldoit,aremadebythemanagementofthecompany�Indoingthis,managersalsomakedecisionsaboutwhatequipmentandmaterialswillbepurchasedandwhatproductiontargetsaretobeachieved�Theyareresponsibleformakingsurethiscanallbedonesafely�

Supervisorsareresponsibleformakingsurethatthemanagement’sdecisionsarecarriedout�Theymakesureproductiontargetsaremet,thatworkiscarriedouttothestandardrequiredandthatproceduresarefollowed�

Employeesdohavearoletoplayincreatingasafeworkplaceandinkeepingitthatway,buttheyareonlyabletomeettheseresponsibilitiesifproceduressuchasPPEandreportingsystemsareinplace�

Foralltheoccupationalhealthandsafetyactivitiesthathappen,orshouldhappeninaworkplacethereneedstobepeopleresponsiblefor:

• initiatingtheactionstobeundertaken;

• developingtheactionsintosteps(procedures);

• trainingotherstofollowtheprocedures;

• supervisingpeopletomakesuretheyunderstandandfollowtheprocedures;and

• reviewingtheprocedurestomakesuretheyworkandupdatingthemasthingsintheworkplacechange�

Step 2: Plan to work safely

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ThewaytosystematicallyplanandmanagehealthandsafetyintheworkplaceistobuildriskmanagementandconsultationintoallthoseactivitieswhichhaveOHSimplications�Aswehaveseenthisinvolvesbusinessactivitiessuchas:

Purchasing: becauseOHSissuescanbethoughtaboutandaddressedbeforeapieceofplantorachemicalevenenterstheworkplace�

Work methods or becausejobscanbedesignedtomake procedures: sureworkersaresafeandthatthejobiscarriedout

inasafemanner�

Using contractors: becauseemployersneedtomakesurethatotherworkerswhocomeintotheworkplacearenotputatriskorthattheactionsoftheseworkersdon’tputatriskthesafetyofanyoneelse�

Reporting OHS becauseifhazardsareidentifiedand problems: reportedassoonassomeonenoticesthemthenthe

riskscanbeexaminedandfixedbeforetheycauseanyharm�

Investigating becauseifsomethingdoesgowrongprocedures incidents: andworkmethodsneedtobereviewedtomake

surethatthesamethingwillnothappenagain�

Emergency becauseriskstopeoplefromfireandother procedures: emergenciesneedtobeidentifiedand

plannedfor�

Next,youneedtodecidehowyouaregoingtoinvolveyouremployeesintheprocess�WillyoudothisviaanOHSCommitteeorbyusingemployeeOHSRepresentatives?Howwilltheseconsultativearrangementsbedevelopedwiththeworkforceandcommunicatedtothem?WorkCoverhasdevelopedaCodeofPractice:OHSConsultationwhichprovidespracticalguidanceonhowyoucansetupconsultativearrangementsandmakesuretheyworkeffectively�

Youthenneedtodevelopanactionplaninconsultationwithyouremployees�Thisactionplanneedstospelloutwhatneedstobedone,inwhatorder,whoisgoingtodoit,andinwhattimeframe�Forexample:

“Purchasing procedures to include identification of hazards and assessment of risk. To be developed by Production Manager and Purchasing Officer and referred to committee in 1 month”.

“Three representatives from the Committee to develop draft evacuation procedures within 2 months”.

Probablythemostimportantpartofyouractionplanwillbetolookatthejobspeopledoinyourworkplaceanddevelopsafeworkproceduresforthesetasks�Ifyoudevelopsafeworkproceduresforthejobswhichformthecoreofyourbusinessoperationthenyouarelikelytoaddressthemajorityofhazardsandrisksinyourworkplace�

Step 3: Involve employees in the process

Step 4: Develop procedures

Step 5: Train people in the procedures

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Todothisyouneedto:sitdownwiththecommitteeoremployeerepresentatives(orinaccordancewithotherconsultativearrangementsyouhaveagreedtowithyouremployees);listallthejobswhicharedone;prioritisethemintermsofriskandthen,establishascheduletodevelopsafeworkproceduresforthesejobsoverasetperiodoftime�AttheendofthisbookletthereisanexampleofhowyoucananalysethetasksinyourworkplaceanddevelopSafeWorkProcedures�Thereisalsoanexampleofhowyoucanlookatyourpurchasingprocedurestoensuresafetyissuesareadequatelyaddressed�

Proceduresdon’tworkifpeopledon’tknowaboutthem�Onceprocedureshavebeendevelopedtoincludetheworkactivitiesdiscussedabove,employeesneedtoknowaboutthem�

ClearlywrittenandstraightforwardprocedurescanbeusedasthebasisforanOHStrainingprogramforalllevelsoftheorganisation�Managers,supervisorsandemployeesallneedinformationandinstructiononwhatisrequiredandwhatisinplace�

Thissameinformationcanbestreamlinedtoformthebasisofanemployeeinductionhandbooktomakesurepeopleareinformedonhowtoworksafelybeforetheycommenceonthejob�

Onceprocedureshavebeeninplaceforawhile,itisimportanttomonitortheireffectivenessandtomakesurethatpeoplearefollowingthem�Reviewingwhatisinplaceandhowitisworkingallowsforthesystemtobechangedtoaccommodateanychangesintheworkplace�Thiswillresultinasystemwhichiscontinuallybeingimproved�

Evaluatingandreviewingmeanscheckingtoseeifthedecisionsthatweremadeabouttherisksandthebestwaytocontrolthemareproperlyputintoplaceandthattheyareworking�

Onceariskassessmenthasbeendoneitmustbereviewedbybothmanagementandthepeopleinvolvedinthejob�Theeffectivenessofthedecisionswhichcamefromtheassessmentneedtobere-evaluatedif:

• thereisevidencethattheriskassessmentisnolongervalid;or

• ifsomeoneisharmedfromexposuretothehazardthattheassessmentdealtwith;or

• iftherearechangesintheworkenvironmentortheworkpracticesconcerningthehazardwhichtheriskassessmentaddressed�

Step 6: Monitor, review and improve the system

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Whilesystematicriskmanagementtriestomakesurethatproceduresareinplacesothatallworkandallrelatedworkactivitiesarecarriedoutsafely,inrealitynewhazardswillariseintheworkplaceforvariousreasons�Oldproblems,whichyouthoughtyousolved,mayreappear�

Asanessentialpartofariskmanagementsystem,everyoneintheworkplaceshouldbeencouragedtoreportproblemsassoonastheynoticethem�

Thehazardreportingsystemshouldrewardpeopleforreportingaproblem,notdiscouragethemforfindingmoreproblems�Itisalsoagoodideatohavesomewayofwritingdownthehazardwhenitisfound,recordingwhatisdonetofixit,andsigningoffwhenitisdone�

Riskmanagementsystemsreducethelikelihoodofanaccidentoccurring,neverthelessfromtimetotimeincidentsoraccidentsmayhappen�Sucheventsinthemselvesareanimportantpartoftheriskmanagementprocess�Let’sexplorewhy�

Anaccidentinvolvesaninjuryorillnessofsomedegreetoapersonintheworkplace�Anincidentornearmiss,ontheotherhand,isaneventwherenoinjuryorillnessoccursbutthisismoretheresultofgoodluck�

Anearmissorincidentshouldbetreatedasawarningsign�Everyoneshouldbeencouragedtoreportthesepotentialaccidentsinthesamewaythattheyareencouragedtoreporthazards�Oncereported,nearmissincidentsshouldbeinvestigatedandcontrolmeasuresputinplacetomakesurethesamethingdoesnothappenagain�

Investigatingaccidents,incidentsor‘nearmisses’helpsyoutofindoutwhatwentwrong,whyithappenedand,ifacontrolmeasurewasinplace,whyitfailed�Perhapsthecontrolmeasurewhichyouthoughtwasinplacedidnotworkbecausepeopleattheworkplacedidnotknowaboutit�

Forexample,maybeyouhadgonetothetroubleofwritingdownsafeworkproceduresbutyouhadnotspentthetimetomakesureallworkerswerefamiliarwiththemandunderstoodthem�Ormaybetherewasacasualworkeronsitefortheweekandheorshehadnotbeenproperlytrainedinyoursafeworkprocedures�Perhapsyouhadbeenbusyandoverlookedthemaintenancescheduleforthemachineryorforgottentobuymoregloves�

Investigatingwhatwentwrongandwhy,andwhatneedstobedonetomakesurethesamesituationwillnotberepeated,isalsopartoftheriskmanagementcycle�

Thelossordisruptionwhichacompanycanexperiencewhenahazardousincidentoccursintheworkplacecanbemultipliedtenfoldwhenthatincidentleadstoaninjurytoaworker�

Acomprehensiveriskmanagementsystemmustthereforeaddresswhatneedstohappenshouldaninjuryoccurandshouldincludea

What if Something does go Wrong?

Reporting Problems

Accident/Incident Reporting

Investigating Accidents, Incidents or ‘Near Misses’

Accidents are not just bad luck or unforeseeable. In most cases they occur as the result of a “chain of events” and a failure of one or more links in that chain.

Injury Management

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well-thought-outplantomaximiseopportunitiesforinjuredworkerstoremainatwork�

Thetwokeyfactorswhichinteracttoreducetheeffectofaworkplaceinjuryforboththeinjuredworkerandtheemployerareearly intervention and early return to work�

Accordingly,yourriskmanagementsystemmustdefinestepstomanageinjuriesandreturninjuredworkerstogainfulemployment�Itneedstoinclude:

• earlynotificationoftheinjury;

• earlycontactwiththeworkerandhis/herdoctorandyourinsurancecompany;

• theprovisionofsuitabledutiesasearlyaspossibleforanearlyreturntowork;and

• awrittenplantoupgradethesedutiesinlinewithmedicaladvice�

Itisimportanttonotethatthesafeworkproceduresgeneratedaspartofyourriskmanagementprocesscanbeusedtofindandspecifysuitableduties�

Systematicmanagementhelpsemployerstorecognisehazardsandplantoeliminateorcontrolrisks�Theoppositeapproachistoignorethepotentialforharmattheplanningstageandthenmanagetheproblemwhenitdoesarise�Thisapproachisfarmoredisruptiveandusuallymorecostlyandriskyintermsofnon-compliance�

Themessageisthattheriskmanagementobligationsshouldnotbeseenasanimpositionoranaddedextrabutwill,whenappliedeffectively,helpemployersplanandorganisetheirworkplaceinanefficientandsafemanner�

Let’sconsiderthefollowingexamplestoseehowthesystematicapproachtoriskmanagementworks�Theseexampleswillillustratethatthesystematicmanagementofhealthandsafetyisthesameasanygoodbusinessplanningstrategy�ItshouldbeemphasisedthatthesearenottheonlysituationsinwhichOHSissuesarisebuttheyprovideusefulillustrationsofhowOHSissuescanbeintegratedingeneraldecisionsabouthowabusinessororganisationoperates�

Conclusion

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Thisexampleillustratestheapplicationofriskmanagementprinciplestodesigninganewjoborsetofjobs�

Artlightisasmallcompanythatassembleslampstands�Thelampbaseshavetraditionallybeenmadeoutofplasticorglazedcrockery�Ithasbeendecidedtoaddanewlinewithcastmetalbases�Thiswillrequiretheemploymentofanewpersontoundertakethefollowingtasks:

• unloadingthetruck;• usingthegrindertodresscasts;• cleaningdressedcastswithsolvent;• placingcastsontrolleytobetakentopaintshop�

Thequestionstoaskare:

1. What hazards and risks are being introduced into the workplace as a result of this new process?

2. How will the hazards be identified?

3. How might the risks be eliminated or controlled?

Listedbelowarethehazardswhichthisnewprocesswouldintroduceintotheworkshop�

Task: Hazard:

Loading/Unloading ManualHandling materials

OperatingGrinder MechanicalPlant/Machinery

UsingSolvents HazardousSubstances

Thetasksobviouslyinvolveexposuretosignificanthazards,namelymanualhandling,plantandhazardoussubstances�

Therisksassociatedwithmanualhandling,theuseofplantandhazardoussubstances,needtobeassessedtodeterminewhatactionshouldbetakentoeliminateorcontrolthem�

• FollowtherecommendationsontheMSDS�

TheMSDSgivesinformationonthehealtheffectsofthesolvent�Asthesolventisalreadybeingusedintheworkplace,theMSDSisreadilyavailableandwarnsthatifnotusedcorrectly,itcancauseheadaches,skinirritationordermatitis,aswellasirritationtotheeyes,nose,throatandrespiratorytract�Italsoadvisesthatpeopleshouldnotbeexposedtothesubstanceforlongperiodsandthatitmustbeusedinawell-ventilatedarea�

• Followtherecommendationsontheoperator’smanual�

Thegrinderwassuppliedwithanoperator’smanualwhichgivesdirectionsonhowtouseitsafely�Themanualwarnsthat:onlythespecifiedmodelgrinderwheelsshouldbepurchasedtoreplacewearingwheels;eyeprotectionshouldbewornatalltimes;andthesafetyguardmustnotberemovedwhenthegrinderisoperating�Whilethemanualindicatesthatthenoiselevelsfromthegrinderarewithinthelegallyspecifiedlimits,itdoessuggestthatwith

Example 1: Job design

Step 1: Hazard Identification

Step 2: Risk Assessment

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prolongeduseoveran8-hourshift,earmuffsshouldbeworn�Themanualcontainsaservicelogforthegrinderandsuggeststhattoprolongthelifeofthegrinderandtoensurethesafeoperationofthemachine,itbeservicedbyaqualifiedpersonevery3months�

• Useinformationaboutaccident,incidentor‘nearmiss’

ExaminationoftheRegisterofInjuriesshowsthatoverthepast5yearstherehavebeen22reportsofaback,neckorshoulderinjuryfromloadingandunloadingtrucks,6ofthesewereveryseriousandresultedintimeoffwork�Inaddition,4peoplehavegonehomewithheadachesandsoreeyesreportedlyafterworkingfor3dayswiththesolvent�

Task: Hazard: Risk:

Loading/Unloading ManualHandling Strainsduetoincorrectmaterials orexcessive • Lifting • Bending • Reaching • Carrying

OperatingGrinder Mechanical Injurycausedby: Plant/Machinery • Movingparts • Metalfragments • Explosion • Noise • Dust • Poormaintenance

UsingSolvents Hazardous Exposureresultingin: Substances • Headaches • Skinirritation • Dermatitis • Eyeirritation • Nose&throatirritation • Respiratoryirritation

Nowthattheriskshavebeenassessed,thenextstepistodevisestrategiestoeliminateorcontrolthoseriskssoastomaketheworkplaceassafeaspossibleandtomakesurethatArtlight’sOHSobligationsaremet�Let’slookattherangeofcontrolstrategiesthatcouldbeconsidered:

Level 1 Controls:

Whydesignisaprobleminthefirstplace?ThinkfirstaboutthepossibilityofELIMINATINGtheriskaltogether�

Is it possible for Artlight to have casts dressed & cleaned as part of supply contract? Thiswouldeliminatetheneedtousethesolventorthegrinderandthereforeeliminatetheassociatedrisksaltogether�

AfterfurtherinvestigationArtlightdiscoversthatthecostofbuyingthecastsalreadydressedandcleanedisprohibitivesoeliminatingtheproblemisnotpossible�Theythereforeneedtoconsiderstrategiestoreducetheproblem�

Step 3: Eliminate or Control the Risks

Level 2 Controls:

Ifyoucan’teliminatetherisk,thinkaboutredesigningtheequipmentorprocessessothatlesshazardousequipmentormaterialscanbeused:

Is it possible to substitute a less hazardous substance for the solvent? There may well be other products that can do the job required and are far less hazardous.

Is it practical to obtain the solvent in smaller containers and so eliminate the risks of skin and eye contact associated with decanting?

Is it possible to have the casts delivered on pallets and transported by a forklift to minimise lifting?

Theworkershavesuggestedthatacratecouldbedesignedwithagravityfeedgatewhichallowsthecaststoberemovedfromthebottomofthecrate�Thiswouldavoidbendingintothecrateandwouldallowthecratetobeplacedonatableatwaistheight,preventingbendingaltogether�

Thegrindershouldbecheckedtomakesuretheappropriateguardsarefittedtominimiserisksofentanglement,andafaceshieldcanbesuppliedforrisksfrommetalfragments�

Anynoiseproblemmaybereducedbyanacoustichood�

Tominimiserisksfromsolventfumes,theareainwhichthesolventistobeusedwillneedtobeproperlyventilatedandmayrequireanappropriateexhaustsystemtobeinstalled�

Level 3 Controls:

Becauseitisnotpossibletoeliminatethehazardbuttheriskcanbeminimisedbyengineeringcontrols,Artlightmustconsidertheneedtosupplementthesecontrolswiththefollowing:

Safe Work Procedures: whichclearlydefinehowpeoplearetodotheirworksafely(workmethods);

Training and Supervision:tomakesureworkersknowhowtodothejobthesafewayandworkaccordingtothesafeworkprocedures;

Personal Protective Equipment:thismayinvolvegloves,eyeandhearingprotection�Aswell,safetyfootwearmaywellbeneededforthetasksassociatedwithmanualhandling�

ThebestcontrolstomanagetherisksatArtlightarelistedinthetablefollowing�

WhatwehavedoneinthefollowingtableiscompleteaRiskAssessmentofthisnewprocessatArtlight�Thisprocessrequiresthatyouthinkmorecarefullyabouthowworkistobedoneintheworkplace�Theadvantageofthisapproachisthatitwillenableyouto:

1. Address problems early:Itismucheasierandmorecost-effectivetodealwithOHSproblemsatthisstageratherthanwaituntilanaccidentorincidentforcesituponyou�

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2. Incorporate safety procedures into work practices rather than addressing safety as a separate issue:Byconsideringsafetyissueswhenajobisdesignedorredesigned,youcanassessthebestwaytodoajobandwhatequipmentisneeded�

Task: Hazard(Problem): Risk(Harm): Controls(Solution):

Loading/ ManualHandling Strainsdueto Unloading incorrector materials excessive: • Lifting • purchasefromsupplier incratesonpallets • Bending • unloadwithforklift • Reaching • placecratesonwaist- hightable • Carrying • gateincratefor gravityfeed

Operating Mechanical Injurycausedby:Grinder Plant/Machine • Movingparts • faceshieldtobe supplied • Metal • grindertobeguarded fragments • Explosionof • onlymodelofwheel grinderwheel specifiedin manufacturer’smanual tobeused • Noise • acoustichoodtobe fitted • hearingprotectiontobe supplied • Dust • extractionsystem • Poor • quarterlymaintenance maintenance servicebyfitter

Using Hazardous ExposureresultingSolvents Substances in: • Headaches • non-solvent-based cleanertobeused • Skinirritation • buysmallcontainersof solvent/nodecanting • Dermatitis • glovestobesupplied • Eyeirritation • eyeprotectionto besupplied • Nose&throat • exhaustsystemto irritation beinstalled • Respiratory irritation

Whileithasbeeneasiertoillustratetheprocessofjobdesignbythisexampleusinganewjob,itisveryimportanttounderstandthatthesamethinkingandthesameprocessneedstobeappliedtoexistingjobs�Whileyoumightthinkthisisharderitreallyjustinvolvesyouandyouremployeesthinkingdifferentlyabout“the way things have always been done”and“the safe way the jobs should be done”�

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Artlightisnowreadytocommenceproduction�Itneedstorecruitanewpersontorunthecastmetalbaseproduction�Theyfindapersonwithmanufacturingexperiencebutneedtomakesureheorsheknowshowtodothejobsafely,inlinewithhowithasbeendesigned�

Artlightneedstoformallytellhimorheraboutthehazardsinvolvedinthejobandinstructhimorherintheapplicationofthecontrolmeasuresalreadydecidedon�

Thecontrolmeasurescanbewrittenupassafe work proceduresorinstructionswhichinformthenewemployeehowtodothejob�Thesafeworkproceduresforthemetalcastproductionwouldlooklikethetablefollowing�

Thesesafeworkproceduresneedtobeexplainedanddemonstratedtothenewworker�Employeesneedinformationandinstructiononwhatisrequiredofthemtoworksafelyandwhatisinplace�Proceduresdon’tworkifpeopledon’tknowaboutthem�Byturningthecontrolstrategiesintosafeworkprocedures,writingthemdown,andtellingpeopleaboutthem,youmakesurethateveryoneistrainedtodothejobsafely�

Thisisparticularlyimportantwhenyouhaveworkerswhoarenewandwhoareunfamiliarwiththetaskandtheequipment,andwhomaybeusedtoworkingdifferently�InductingnewstaffinOHSdoesnotonlyapplytosafeworkproceduresbutshouldcoveralltheOHSrequirementsofthecompanysuchas:OHSresponsibilities;hazardreporting;accidentreporting;firstaid;injurymanagement,etc�

Becauseeveryoneintheworkplaceneedstoknowaboutsafeworkproceduresandotherriskmanagementactivities,writingthemdownassimpleprocedures,asshowninthetablefollowing,allowsyoutostructureyourorganisation’sOHStrainingprogram�Thistellsyouwhatpeopleneedtoknowaboutworkingsafelyatyourworkplace�Thecontentofyourtrainingprogramshoulddirectlyreflecttheprocedures�

Example 2: Safe Work Procedures and Training

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Task: Metal Cast Production Safe Work Procedure:

Loading&• Allmaterialswillbesuppliedincratesonpallets�Ifmaterialsunloading arenotdeliveredonpallets,donotacceptthegoodsfrommaterials thesupplier�Immediatelycontacttheworkshopmanager�

• Allmaterialsaretobeunloadedfromtruckusingforklift,drivertobecertificated�

• Thecratesaretobestackedontopofeachotherinthestorearea,nomorethantwocrateshigh�

• Whenmaterialsarerequired,onecrateatatimeistobeforkliftedontothedesignatedworkbench�

• Removecastsfromcratebyliftinggateonsideofcrateandcastswillgravityfeedontoworkbench�

• Avoidbendingintocratetoremovecasts�

• Allfinishedproductsaretobepackedandreloadedintothecratesandforkliftedontothetruckfordelivery�

Operating • OnlythoseemployeeswhohavebeenspecificallyinstructedGrinder tooperatethegrinderareallowedtouseit�

• Theguardonthegrindermustbeinitsfixedpositionwhengrinderinoperation�

• Ifyounoticeanyproblemwiththeguard,switchoffthegrinderandreporttheproblemimmediatelytotheworkshopmanager�

• Theguardmustneverberemovedbyanyoneotherthanthemaintenancefitter�

• Thefaceshieldsuppliedmustbewornatalltimeswhenoperatingthegrinder�

• Theextractionsystemmustalwaysbeswitchedonwhengrinderinoperation�

• Theacoustichoodmustbeclosedatalltimeswhilethegrinderisinoperation�

• Theearmuffssuppliedmustbewornwhenoperatingthegrinder�

• Onlythemodelwheelspecifiedinthemanufacturersmanualwillbepurchasedandusedtoreplacewornwheels�

• Theworkshopmanagerwillmaintainmaintenancelogbookandarrangeforthegrindertobeservicedbyaqualifiedfitterquarterly�

Using • Cleaningsolventissuppliedin1litrecontainersandisnottoSolvent bedecantedintoothercontainersunderanycircumstances�

• OnlythoseemployeeswhohavereadtheMSDSandhavebeeninstructedinthesafeuseofthesolventaretoperformthistask�

• Glovesmustbewornatalltimeswhenusingthesolvent�

• Eyeprotectionmustbewornatalltimeswhenusingthesolvent�

• Caremustbetakennottoexposetheeyes,skin,noseorthroattocontactwiththesolvent�

• Themainexhaustsystemmustbeturnedonatalltimes�

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“Buyingin”OHSproblemscanalsobepreventedbyaplanned,systematicapproachtopurchasing�Thismeansthinkingaboutthehazardsthatnewproductsmaypresentandwhatriskstheywillimposeonthecompanybeforeyoubuytheriskin�

Fromtimetotimebusinessesneedtoconsiderpurchasingequipment�Thismaybetoreplacecurrentequipmentoritmaybenewequipmenttomakeaworkprocesseasierormoreefficient�

Likewise,thebusinessmayneedtoconsiderpurchasingsubstancessuchassolvents,detergents,andlubricants�Thesemaybetoreplacecurrentsubstancesbecausenewoneshavecomeonthemarketandareeithercheaperormoreeffectiveoranewprocessisbeingintroducedintotheworksystem�

Allorganisationshavesomeoneresponsibleforthepurchaseandapurchasingpolicy,nomatterhowinformal�Suchapolicyisbasedon:

•  Cost:  Value for Money•  Efficiency:  It does the job well•  Maintenance:   How reliable and what’s the supply like?

Thesearealwaysthefactorswhichinfluencedecisionstopurchaseornottopurchase�

Theintroductionofnewplantandsubstancescanposesignificanthealthandsafetyriskstopeopleintheworkplace�Thedecisiononwhatparticularpieceofequipmentorsubstanceiseventuallypurchasedshouldnotbebasedonlyoncost,efficiencyandmaintenancebutshouldbedeterminedbydecisionsconcerning:

•  What hazards are associated with the product?•  What risks will the product introduce?•  What control strategies need to be implemented to control  the risks?

Aprocedureneedstobedevelopedtomakesurethesefactorsareconsideredbeforethepurchaseismade�Itismucheasierandmorecost-effectivetoaddressthesehealthandsafetyissuespriortopurchaseratherthanafter,whentheneedtoimplementcostlycontrolmeasurestoaddresstheOHSconsequencesofthepurchasingdecisionmayberequired�

Therefore,apurchasingpolicyneedstobebasedonconsiderationofOHSinformation�ThisinformationwillenableyoutomakeaninformeddecisiononwhatyoupurchaseintermsofyourOHSresponsibilities�Bydoingthisyouwillknow:

•  the hazards and risks associated with the product; and

•   what work systems need to be implemented to ensure the health  and safety of employees.

Then,youcanpurchasetoeliminateorminimisetherisks�

Example 3: Purchasing decisions

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Notes

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Notes

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Notes

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Catalogue No. WC00425 WorkCover Publications Hotline 1300 799 003

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