Department :

ESD AND WORKSHOP

Last Update:
dd/mm/yy

Section/Area:

Job Activity:

HAZARD IDENTIFICATION,
RISK ASSESSMENT & DETERMINING CONTROL

(HI RA DC)

Prepared by:

Reviewed by:

Approved by:

(Team Leader of Appointed Review Team)

(EHS / Area Supervisor)

(Section / Department Manager)

Date:

Date:

Date:

HAZARDS IDENTIFICATION

Condtion
No.

Main Activity
(List down in
sequence)

(The tasks
were carried
out during
which
condition?)

Sub- Activity

Hazards Desription

(Explain detail tasks while

carry out the Main Activity)

(Explain what is the source of danger while task

is carried out)

1. Print Checklist of
stock count from
system

1. Broken socket

2.Store room
hallways

1. Floor slippery (wet condition)

RISK ASSESSMENT

Consequences
(Explain what type of injury may
happen if source of danger is not
being taken care of)

Initial
Risk
F
L
S
(Frequency) (Likelihood) (Severity) Rating

Sig?

(IRR)

20

II

1.0

20

II

20

1.0

20

II

20

1.0

20

II

20

1.0

20

II

30

1.0

30

III

30

1.0

30

III

30

1.0

30

III

NS

NS

NS

NS

NS

NS

4. Check asset list

and verify against
nos of part in the
store

20

2. Accident occur / Injury

20

1. Body Injury

20

2. No electricity / light in the room 2. Injury

1. Sick Building
1. Poor Ventilation
Syndrome, SBS
2. Air condition is not funtioning 2. Migraine / Headache
1. Poor Housekeeping, broken
1. Injury
wire
2.Part not arrange properly
2. Body Injury

3. Sharp object lying on the floor

Risk
Cat.

1.0

3. Count part in the

store room

Final
Any
Risk
Related
Legal
(What action has been (Is the ECM Rating
Effective?) (FRR)
taken to tackle the
issues?)

II

ECM
Factor

20

Existing Control
Measures
(ECM)

1.0

STOCK
COUNT

1. Short circuit

DETERMINING CONTROLS

2. Wiring lying on the floor

3. Fatal / Accident

Signage

1.
2.
3.
4.
5.

Elimination of aspects,
Isolation,
Substitution,
Engineering,
Administrative

Department :

ESD AND WORKSHOP

Last Update:
dd/mm/yy

Section/Area:

Job Activity:

HAZARD IDENTIFICATION,
RISK ASSESSMENT & DETERMINING CONTROL

(HI RA DC)

Prepared by:

Reviewed by:

Approved by:

(Team Leader of Appointed Review Team)

(EHS / Area Supervisor)

(Section / Department Manager)

Date:

Date:

Date:

HAZARDS IDENTIFICATION

RISK ASSESSMENT

Condtion
No.

Main Activity
(List down in
sequence)

(The tasks
were carried
out during
which
condition?)

Sub- Activity

Hazards Desription

(Explain detail tasks while

carry out the Main Activity)

(Explain what is the source of danger while task

is carried out)

Consequences
(Explain what type of injury may
happen if source of danger is not
being taken care of)

Initial
Risk
F
L
S
(Frequency) (Likelihood) (Severity) Rating

Sig?

(IRR)

Category

Risk Assessment Criteria

Frequency of the
Activity

Likelihood of Hazard to
Occur

> 1 year

Very unlikely

1 / 6 months

1 / 3 months

Once per month

> 1 time / months

Unlikely

Likely

Most likely

Certain

Cost

Negligible
-First aid

No property damage/
< RM 5k

Minor
-<4 days MC

RM 5 ~ 10k

Existing Control
Measures
(ECM)

ECM
Factor

Final
Any
Risk
Related
Legal
(What action has been (Is the ECM Rating
Effective?) (FRR)
taken to tackle the
issues?)

Condition of assessment
N

Normal condition

Ab

Abnormal condition

Risk Rating

Risk
Cat.

Risk Level

1-9

Trivial

10 - 25

II

Acceptable

Emergency condition

Elimination of aspects,
Isolation,
Substitution,
Engineering,
Administrative

Action and Time Scale

No action required

Determination of Significant Hazards

Serious
->4 day MC

Decision

Initial RR

NS

1, 2 or 3

= or <25

4 or 5

> 25

RM 10 ~ 100k

Permanent disability

Determination of Any Related Legal

Requirement

RM 100 ~ 1 Million

Fatal

Applicable legal requirement

AP

Applicable Permit to Comply

NIL

Nil

26 - 45

III

No additional controls required.

Monitoring required to ensure existing controls are
maintained.

Moderate

Additonal controls require, either engineering or

administrative controls, and ensure availability of spill
kit/PPE, if relevant
Monitoring require to ensure existing conrols and additional
controls are adequately implemented

Significant

To implement program and/or operational controls, e.g.

engineering and administrative control, ensure availability
of spill kit/PPE, if relevant
Continuing monitoring to ensure comply with the applicable
legal/regulatory requirement

Extensive

To implement program and/or operational controls, e.g.

engineering and administrative control, ensure availability
of spill kit/PPE,
If relevant, ensure the permit is maintain valid, or
application of permit is carried out & constantly follow up

> RM 1 Million

ECM Factor

46 - 85

A
(need to comply
with legal req)

> or = 85

AP
(with permit)

IV

0.1 All applicable controls are relevant, applied and systematically implemented in terms of Engineering, Administrative and PPE/SK.
0.3 All applicable control are applied, however, further control on engineering, administrative and/or PPE/SK is required
0.6 Certain engineering, administrative and/or PPE/SK control are available, however, not adequate or relevant to minimize the risk.
1.0 There's no obvious control on the activity.

Risk
Cat.

1.
2.
3.
4.
5.

Risk Category - Guide for Further Action Plan

Severity of the Consequences to Happen

Safety

DETERMINING CONTROLS

Risk Assessment Criteria

Likelihood of Hazard/Aspects to Occur ( L )
Scale

Frequency of the Activity

(F)

Occupational Safety
Category

Inconceivable

Yearly

Description
Is practically impossible and has
never occurred
Has not been known to occur after
many years

Category

Monthly

Remote

Weekly

Conceivable

Might be occur at sometime in future

Likely

Possible

Has a good chance of occurring and

is not unusual

Most likely

Most likely

The most likely result of the hazard /

event being realized

Certain

Daily
Hourly

Description (criteria)

Description

Very unlikely

Condition of assessment

Environment

Unlikely

N - Normal condition

The probability to happen is

extremely small

Ab - Abnormal condition

Could happen, however very rare

E - Emergency condition

Chances to happen is relatively high

Can happen frequently
Expected to happen

Severity of the Consequences to Happen (S)

Occupational Safety

Environment

Scale
Category

Impact on human
(H)

Category

Negligible

- No or slight injury and not affecting

work performance
- Affecting only personnel involved in
the activity

No or slight impact to
environment

Minor

- Minor injury or health effect

(including first aid case and medical
treatment)
- Affecting work performance, such
as restriction to activities

Limited impact to
environment

Serious

- Major injury or health effect.

- Affecting work performance in
longer term such as prolonged
absence from work within the
department.

Considerable impact to
environment

Impact on ecology
(E)

Impact on financial
(F)
(Economic effect)

- No damage or slight damage

- No interruption to operations.
- No environmental damage or issue. Beneficial impact:
- Recycable resources
- Has economic effect in other areas
than the business concerned (ripple
effect on business)

- Contamination.
- Damage sufficiently to attack the
environmental at incident site.

- Minor damage
- Brief disruption to operations

- Limited loss of discharges of known

toxicity.
- Damage sufficiently to attack the
environmental within the plant.
- Potential for or single exceed of
environmental related statutory
requirement i.e. EQA 1974.

- Localised damage
- Partial shutdown (short period)
Beneficial impact:
- Has economic effect on the
business concerned (ripple effect on
business)

Impact on organization
image (I)
(Concern of interested
parties)

- No or slight public awareness may

exist, but there is no public concern.
Beneficial impact:
- Leads to great improvement of the
image

- Some local public concern.

- State public concern. Considerable

local media and political attention.
- Potential for or single violation of
business related regulation or
statutory requirements i.e. business
license.
Beneficial impact:
- Lead to improvement of the image

Fatal

- Single fatality or permanent total

disability from an incident on
occupational illness (poison).
- Affecting personal within the plant

- Severe environmental damage.

- Damage sufficiently to attack the
- Major damage
Major impact to environment environmental in Shah Alam.
- Partial shutdown (longer period)
- Repeated exceed of environmental
related statutory or prescribed limit.

- National public concern.

- Adverse attention in national media.
- More than single violation of
business related regulation or
statutory requirements i.e. business
license

Catastrophic

- Multiple fatalities from accident or

occupational illness.
- Affecting personal within or outside
the plant

- Persistent severe environmental

damage or severe nuisance
extending over a large area.
- Affecting Selangor community.
- Constant high exceed of
environmental related statutory or
prescribed limits.

- International public attention.

- Extensive public attention in the
national/international media.
- Potentially severe impact on access
or renewal of licenses.
Beneficial impact:
- Not expected to lead to
improvement of the image

Extensive impact to
environment

Factor Degree of existing control measures (ECM)

- Extensive damage
- Total lost of operation
Beneficial impact:
- No economic effect is expected
(ripple effect on business)

Description

0.1

All applicable controls are relevant, applied and systematically implemented in terms of Engineering,
Administrative and PPE/SK.

Full control or control not required

- Can be detected at time of occurrence, both preventive and mitigation measures are available.
- Control measurement available and is effective
- Control not required as impact is very low

0.3

All applicable control are applied, however, further control on engineering, administrative and/or PPE/SK is
required

Immediate control or moderate control required

- Can not be detected at time of occurrence but preventive measure is available, or
- Can be detected at time of occurrence and mitigation measure is available.
- Moderate control measurement available, however not full proof system

0.6

Certain engineering, administrative and/or PPE/SK control are available, however, not adequate or relevant to
minimize the risk.

Delay control or slight control avaliable

- Can be detected only after occurrence and mitigation measure is available.
- Slight Control measurement available, however not effective

There's no obvious control on the activity.

Unable to control or no control at all

- Cannot be detected and no mitigation measure available.
- Control measurement not available

Note: PPE: Personal Protective Equipment SK: Spillage Kit

WWTP

FACILITY

FACILITY

H7

H8

H6

H5

H4

GATE 3

GATE 4
C1
FPI

H2

H1a
C2

LAB

H3

SVC

GATE 2
FPI
GATE 1

L4

H1b

GATE 4
STORE
L1

MAINTENANCE

L3

L2

GATE 1

GATE 2

L5

GATE 3
GATE 5
FPI

LPT

SVC

HPC

maint

vaccum heat treatment

inspection

WWTP + DI water

blending

chemical cleaning

welding

dust collector

welding

FPI - SVC-HPC-LPT

manual grinding

cooling tower

molten salt

HVOF

compressor

vibratory + molydag

arc wire

fire fighting equipment

blasting

DMC + milling + CMM

waste management

peening

normal trouble shooting

inspection

machining
manual grinding
blasting
coating furnace

blasting

Hazards Identification Checklist

Area:

Prepared By:

Date:

(A) Bio-mechanical and Postural

Repetitive or sustained postures, movements or forces as listed below for more than 30 min at a
time, or for more than 2 hours over a workday;
Excessive bending or twisting of back or neck in any direction
Working with hand(-s) above shoulders
Reaching to front/side more than 30 cm from body
Reaching behind body
Squatting, kneeling, crawling, semi-lying or jumping
Standing with most of body weight on one leg
Twisting, turning, grabbing, picking or wringing actions with fingers, hands or arms
Working with fingers close together or wide apart
Very fast movements
Excessive bending of wrist(-s)
Carrying with one hand or one side of the body
Pushing, pulling, dragging, holding or restraining
High force actions as listed below;
Lifting, lowering or carrying heavy loads
Applying uneven, fast or jerky forces
Sudden/unexpected forces
Pushing/pulling objects hard to move or stop
Awkward grips
Throwing, catching, hitting, kicking or jumping
Holding, restraining or supporting person, animal or heavy object

Review By:

Date:

Hazards Identification Checklist

Area:

Prepared By:

Review By:

Date:

Date:

(B) Physical Environment and Workplace Design

Poor housekeeping, uncontained spillages or wastes
Uneven or slippery work surfaces
Obstacles in passageways, near equipment, risk of collision with stationary objects, etc
Inadequate work platforms, stairs, ladders, guardrails, harnesses, etc for work at height
Personnel access within 2 metres of edge of roof, high place of work, etc
Unprotected openings or gaps in walkways & platforms
Poor lighting
Exposure to harmful noise levels
Confusing or inadequate labelling of controls
Mismatch between plant, workplace, office workstation design, activity or task and user physical characteristics (height, strength, speed, mobility, fitness,
etc).
Body parts coming in contact with hot components during testing, inspection, operation, maintenance, cleaning or repair.
Exposure to camp fires and hot items from fires
Fall or collapse of ground, materials, plant, structures, etc
Exposure to extremely cold materials or components (eg dry ice)
Exposure to radiation (ionising and non-ionising, lasers)
Entry into cool rooms

Hazards Identification Checklist

Area:

Prepared By:

Date:

Review By:

Date:

(C )Mechanical
Hair, clothing, jewellery, rags, etc liable to become entangled in moving components
Uncontrolled or unexpected movement of machinery, components, work pieces, vehicles or loads
Inability to slow, stop or immobilise machines, vehicles
Body parts coming in contact with moving, sharp, hot, or "live" components during testing, inspection, operation, maintenance, cleaning or repair
Possibility of traffic accident
Persons or body parts trapped or sheared between moving component & fixed plant, materials or structures
Persons pushed, pulled or thrown off plant, structures
Machines, components, or materials disintegrating (eg grinding wheels)
Persons being injured by damaged, poorly maintained or unguarded equipment (including electricals)
Components, work pieces, fluids, etc being ejected

(D) Electrical
Contact with "live" components during testing, inspection, operation, maintenance, cleaning or repair.
Contact with overhead power lines
Contact with underground power cables
Explosion or ignition of electrical components, etc
Unauthorised access to electrical services, switchboards, controls, etc

(E) Chemicals and Toxicity

Explosion or ignition of gases, vapours, liquids, dusts, etc
Exposure to toxic concentrations of chemicals (skin, inhalation, ingestion, etc)
Exposure to oxygen-depleted atmospheres
Damage to gas lines, compressed gas cylinders, chemical storage containers, etc

Hazards Identification Checklist

Area:

Prepared By:

Date:

(F) Biological and Human

Exposure to venomous or dangerous animals
Exposure to toxic natural substances (plant, mushrooms, gases, etc)
Exposure to (potentially) infectious substances
Accidental collision with another person
Assault by another person

(G) Organisational and Procedural Arrangements

Insufficient first-aid equipment or trained personnel
Insufficient evacuation, emergency or rescue planning and facilities
Access to hazardous equipment by unauthorised or untrained people
Insufficient job rotation, rest breaks
Inappropriate, insufficient or poorly maintained personal protective equipment

(H) Psycho-social Environment and Task Design

Insufficient consideration given to the probability of human error and its consequences
Lack of clarity in work roles of employee(-s)
Lack of control or recognition in work roles of employees
Mismatch between task demands and workers'/people's behaviour or capabilities
Insufficient consideration given to consultation prior to workplace changes

(I) Natural Environment

Drowning
Bushfires
Persons becoming lost or ill in remote locations
Possibility of being engulfed in loose or crumbling ground
Exposure to extreme environmental conditions (hot, cold, dry, wet, snowy, stormy, etc)
Possibility of tree limbs falling
Lightning in exposed locations

Review By:

Date: