HealthSafety
UK health and safety management for MNMUK manufacturing operations, aligned with the Health and Safety at Work Act 1974, UK HSE regulations, and IATF 16949.
Workflow Routing
| Workflow | Trigger | File |
|----------|---------|------|
| RiskAssessment | "risk assessment", "hazard assessment" | Workflows/RiskAssessment.md |
| IncidentReporting | "accident", "incident", "near miss" | Workflows/IncidentReporting.md |
| CoshhAssessment | "COSHH", "chemical", "hazardous substance" | Workflows/CoshhAssessment.md |
| SafetyAudit | "safety audit", "inspection" | Workflows/SafetyAudit.md |
Legal Framework (UK)
Primary Legislation
| Act/Regulation | Requirement | MNMUK Application | |----------------|-------------|-------------------| | Health and Safety at Work Act 1974 | General duty of care | Foundation of all H&S | | Management of Health and Safety at Work Regulations 1999 | Risk assessment, competent persons | Risk assessment programme | | COSHH Regulations 2002 | Control of hazardous substances | Chemical management | | PUWER 1998 | Provision and use of work equipment | Machine safety | | Manual Handling Operations Regulations 1992 | Reduce manual handling risks | Lifting assessments | | PPE at Work Regulations 1992 | Provide appropriate PPE | PPE programme | | RIDDOR 2013 | Report specified injuries/incidents | Incident reporting |
Enforcement
| Body | Role | |------|------| | Health and Safety Executive (HSE) | Primary enforcement authority | | Local Authority | Certain workplace types | | Environment Agency | Environmental hazards |
IATF 16949 Alignment
| IATF Clause | Requirement | H&S Coverage | |-------------|-------------|--------------| | 7.1.4 | Environment for operation | Physical, psychological, social factors | | 7.1.4.1 | Cleanliness of premises | Housekeeping, 5S, safety | | 8.5.1.5 | Total productive maintenance | Equipment safety maintenance | | 7.2 | Competence | H&S training requirements |
Reference: ~/projects/work/docs/work-instructions/procedures/hr/HRP-004_Health_Safety.md
Risk Assessment Framework
UK HSE 5-Step Methodology
All risk assessments at MNMUK must follow the UK HSE 5-step methodology:
| Step | HSE Step | Description | |------|----------|-------------| | 1 | Identify the hazards | Walk the area, consult workers, review SDS/accident history, consider non-routine tasks | | 2 | Decide who might be harmed and how | Employees, contractors, visitors, vulnerable persons; identify exposure routes | | 3 | Evaluate the risks and decide on precautions | Consider existing controls, apply hierarchy of control, use risk matrix to prioritise | | 4 | Record your findings and implement them | Document hazards, persons at risk, existing and additional controls; assign actions with owners and dates | | 5 | Review your assessment and update if necessary | Review after incidents, process changes, or at least annually |
Hazard Categories
| Category | Examples | Assessment Approach | |----------|----------|---------------------| | Mechanical | Moving parts, nip points, ejection | Machine-specific assessment | | Chemical | Coolants, solvents, oils | COSHH assessment | | Physical | Noise, vibration, temperature | Environmental monitoring | | Ergonomic | Repetitive motion, posture, lifting | Workstation assessment | | Electrical | Shock, arc flash | Electrical safety programme |
Risk Matrix (Step 3)
PPE Requirements
PPE by Area
| Area | Minimum PPE | Additional as Required | |------|-------------|------------------------| | Manufacturing floor | Safety glasses, safety footwear | Hearing protection | | Machine operation | + Hearing protection | Face shield for grinding | | Chemical handling | + Chemical-resistant gloves | Face shield, apron | | Welding areas | Welding helmet, leather gloves | Fire-resistant clothing | | Overhead work | Hard hat | Fall protection |
PPE Management
| Requirement | Frequency | |-------------|-----------| | Issue and record | At hire / as needed | | Condition inspection | Daily by user | | Replacement | When damaged or worn | | Training on use | At issue |
Machine Safety
Key Requirements (PUWER)
| Requirement | Standard | |-------------|----------| | Guarding | All nip points, moving parts guarded | | Interlocks | Guards interlocked where practical | | Emergency stops | Accessible within reach | | Maintenance | Safe systems, isolation |
Lockout/Tagout (LOTO)
8-Step LOTO Procedure:
- Notify - Inform affected employees
- Identify - Identify all energy sources
- Isolate - Shut down equipment normally
- Lock/Tag - Apply personal lock and tag
- Release - Release stored energy
- Verify - Attempt start to confirm isolation
- Perform - Complete maintenance work
- Restore - Remove locks/tags, restore energy
Energy Types:
- Electrical
- Pneumatic
- Hydraulic
- Mechanical (springs, gravity)
- Thermal
- Chemical
COSHH Management
Hazardous Substances at MNMUK
| Category | Examples | Controls | |----------|----------|----------| | Cutting fluids | Coolants, neat oils | LEV, PPE, skin care | | Cleaning solvents | Degreasers, IPA | Ventilation, PPE | | Lubricants | Oils, greases | Skin protection | | Welding fumes | Metal fumes | LEV, respiratory protection |
COSHH Requirements
| Requirement | Action | |-------------|--------| | Assessment | For each substance/process | | Control measures | Hierarchy of controls | | Health surveillance | Where required by assessment | | Information/training | All exposed employees | | SDS availability | At point of use |
Manual Handling
Assessment Triggers
| Factor | Assessment Required | |--------|---------------------| | Weight | >10kg regular handling | | Frequency | Repeated lifting | | Posture | Twisting, bending, reaching | | Environment | Space constraints | | Individual | Known conditions |
Control Hierarchy
- Eliminate - Remove need for manual handling
- Mechanise - Hoists, trolleys, conveyors
- Reduce - Lighter loads, team lifting
- Train - Proper technique
Incident Management
Reportable Incidents (RIDDOR)
| Category | Examples | Reporting | |----------|----------|-----------| | Fatal | Any workplace death | Immediate | | Specified injuries | Fractures, amputations, loss of sight | Within 10 days | | Over 7-day incapacitation | Unable to work >7 days | Within 15 days | | Occupational diseases | As specified in RIDDOR | When diagnosed | | Dangerous occurrences | Near misses as specified | Within 10 days |
Investigation Process
- Immediate - Secure scene, care for injured
- Report - Complete incident form
- Investigate - Gather facts, interview witnesses
- Root cause - 5 Whys, fishbone analysis
- Actions - Corrective and preventive
- Close - Verify effectiveness
Emergency Procedures
Emergency Types
| Emergency | Response | |-----------|----------| | Fire | Alarm, evacuate, assemble, account | | Medical | First aid, call 999, assist responders | | Chemical spill | Evacuate area, contain if safe, notify | | Gas leak | Evacuate, no ignition sources, notify |
Emergency Equipment
| Equipment | Location | Inspection | |-----------|----------|------------| | Fire extinguishers | Throughout facility | Monthly visual, annual service | | First aid kits | Each department | Monthly check | | AED | Main entrance, production | Monthly check | | Eye wash stations | Chemical areas | Weekly flush | | Spill kits | Chemical storage, machines | Monthly check |
Drill Schedule
| Drill | Frequency | |-------|-----------| | Fire evacuation | Quarterly | | First aid response | Annual | | Chemical spill | Annual |
Safety Training
Training Matrix
| Training | Who | When | Refresher | |----------|-----|------|-----------| | General safety induction | All employees | At hire | Annual | | Job-specific hazards | Affected employees | At assignment | As needed | | PPE use | All employees | At hire/issue | As needed | | LOTO | Authorized personnel | Initial | Annual | | First aid | Designated responders | Initial | Biennial | | Fire warden | Designated wardens | Initial | Annual | | Forklift/MHE | Operators | Initial | Triennial | | COSHH | Exposed employees | At assignment | Annual |
Safety Audits
Audit Programme
| Audit Type | Frequency | Scope | |------------|-----------|-------| | Department inspection | Weekly | Area-specific hazards | | Safety committee | Monthly | Rotating areas | | Management review | Quarterly | Programme effectiveness | | External audit | Annual | Full compliance |
Audit Focus Areas
- Housekeeping and 5S
- PPE compliance
- Machine guarding
- Chemical storage
- Emergency equipment
- Documentation currency
Performance Metrics
| Metric | Target | Frequency | |--------|--------|-----------| | Recordable incident rate | <2.0 | Monthly | | Lost time incident rate | <1.0 | Monthly | | Near miss reports | >5/month | Monthly | | Training completion | 100% | Monthly | | Audit score | >90% | Monthly | | Open actions | <5 overdue | Weekly |
Record Retention
| Record | Retention Period | |--------|------------------| | Risk assessments | 3 years (or while valid) | | Training records | Employment + 7 years | | Incident reports | 10 years | | RIDDOR reports | 10 years | | COSHH assessments | 40 years | | Health surveillance | 40 years | | Audit records | 3 years |
Integration with Other Skills
| Skill | Integration Point | |-------|-------------------| | AutomotiveManufacturing | Process safety in procedures | | Pfmea | Safety failure modes | | Assemblyoperations | Assembly-specific hazards | | Maintenancepm | Equipment safety checks | | Tribalknowledge | Safety practices capture |
Examples
Example 1: New machine installation
User: "We're installing a new CNC lathe"
→ Conduct risk assessment (Workflows/RiskAssessment.md)
→ Verify guarding per PUWER
→ Develop LOTO procedure
→ Train operators
→ Update department risk assessment
Example 2: Chemical spill incident
User: "We had a coolant spill in Machine Shop"
→ Ensure immediate response complete
→ Complete incident report (Workflows/IncidentReporting.md)
→ Investigate root cause
→ Review COSHH assessment
→ Implement corrective actions
Example 3: New substance introduction
User: "We want to use a new degreaser"
→ Obtain SDS from supplier
→ Conduct COSHH assessment (Workflows/CoshhAssessment.md)
→ Determine controls required
→ Train affected employees
→ Update chemical register