AIT Machine Risk Assessment, Mitigation, & Contingency Plan

Risk Matrix
Likelihood Health, Safety, Environmental
Descriptor Level Definition
Rare Level 1 The event may occur only in exceptional circumstances
Unlikely Level 2 The event may occur at sometime, say once in 10 years
Possible Level 3 The event should occur at sometime, say once in 3 years
Likely Level 4 The event will probably occur in most circumstances, say once a year
Almost Certain Level 5 The event is expected to occur in most circumstances

Consequence Health, Safety, Environmental

Descriptor Level Definition
Insignificant Level 1 No Injury
Minor Level 2 Injury/ill health requiring first aid
Moderate Level 3 Injury/ill health requiring medical attention
Major Level 4 Injury/ill health requiring hospital admission
Severe Level 5 Fatality

Likelihood Product Quality & Delivery

Descriptor Level Definition
Rare Level 1 The event may occur only in exceptional circumstances
Unlikely Level 2 The event may occur at sometime, say once in 10 years
Possible Level 3 The event should occur at sometime, say once in 3 years
Likely Level 4 The event will probably occur in most circumstances, say once a year
Almost Certain Level 5 The event is expected to occur in most circumstances

Consequence Product Quality & Delivery

Descriptor Level Definition
Insignificant Level 1 No affect on Quality or Delivery of Product
Minor Level 2 Product Quality & Delivery is impacted slightly
Moderate Level 3 Customer notification is required for acceptance or extension
Major Level 4 Product Quality & Delivery is delayed more than one month
Severe Level 5 Product Quality & Delivery is delayed indefinitely

Risk Matrix
Likelihood Consequence
Insignificant Minor Moderate Major Severe
Almost Certain HIGH HIGH EXTREME EXTREME EXTREME
Likely MEDIUM HIGH HIGH EXTREME EXTREME
Possible LOW MEDIUM HIGH EXTREME EXTREME
Unlikely LOW LOW MEDIUM HIGH EXTREME
Rare LOW LOW MEDIUM HIGH HIGH

Key
Extreme: Notify supervisor and/or QHSE Manager immediately. Stop Action/task/process immediately. Corrective actions should be taken immediately. Must have
High: contingency
Notify plansand/or
supervisor in place for risks
QHSE affecting
Manager product quality
immediately. or delivery.
Corrective actions should be taken within 48 hours of notification. Must have contingency plans in place
Medium: for riskssupervisor
Notify affecting and/or
productQHSE
qualityManager.
or delivery
Nominated employee, QHSE or Department Manager is to follow up that corrective action is taken within 7 days. If
Low: established
Notify operationg
supervisor procedures
and/or do not mitigate
QHSE Manager. the risk,
Nominated must have
employee, QHSEcontingency plansManager
or Department in place for
is torisks affecting
follow up thatproduct quality
corrective or delivery.
action is taken within a reasonable
time. Established Operating Procedures mitigate low risks affecting product quality or delivery.

Risk Controls
Elimination Completely remove the hazard e.g. removal of hazardous substance from the workplace.
Substitution Change a work practice, employee, substance or piece of equipment to provide a safer environment e.g. substitute old office chairs to ergonomic chairs to reduce
Engineering the risk of
Modify theergonomic injuries
design of the or the and/or
workplace cross-training of competent
environmental individuals,
conditions e.g. the or
usehiring of a qualified
of a "paint locker" replacement.
to contain hazardous/flammable chemicals, or utilizing tooling
Administrative made of higher
Developing quality, and
procedures or performing
systems topreventative maintenance
control the interaction between people and hazards e.g. reducing the amount of time of exposure to noise by requiring
Personal Protective people to wear PPE
Implementing hearing protection,
to prevent providing
physical manual
contact handling
between training
a person and ato persons
hazard e.g.soANSI
they certified
are bettersteel-toe
able to identify/report/control/avoid
boots, safe glasses, ect. hazards in the workplace,
Equipment (PPE)

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, & Contingency Plan
Risk Rigister

Risk # Date: Category (facility, HSE, ect) Description:

1 5/3/2014 HSE Bodily Injury
2 5/3/2014 HSE Lifting device failure
3 5/3/2014 HSE Electric shock, mangled body-- LOTO
4 5/3/2014 HSE Dehydration, heat exhaustion
5 5/3/2014 HSE foreign particles in eye, skin, lungs
6 5/3/2014 HSE contact, ingestion, or inhalation of hazardous chemicals
7 5/3/2014 Facility loss of power (external)
8 5/3/2014 Facility loss of power (internal)
9 5/3/2014 Facility fire
10 5/3/2014 Facility chemical spill
11 5/3/2014 Personnel Employee sick or on vacation
12 5/3/2014 Personnel Employee quit or was terminated
13 5/3/2014 Personnel Employee incompetence
14 5/3/2014 Key equipment Overhead & Jib Crane failure
15 5/3/2014 Key equipment Lifting Device Failure (slings, chains, wire rope, magnets)
16 5/3/2014 Key equipment Forklift failure
17 5/3/2014 Key equipment Company Truck Failure
18 5/3/2014 Key equipment Horizontal Mill mechanical breakdown
19 5/3/2014 Key equipment Mill mechanical breakdown
20 5/3/2014 Key equipment Lathe mechanical breakdown
21 5/3/2014 Key equipment Saw mechanical breakdown
22 5/3/2014 Contract Review/Product Realization Customer changes scope/specifications
23 5/3/2014 Contract Review/Product Realization Customer requires process we aren't familiar with
24 5/3/2014 Contract Review/Product Realization Customer gives no specifications, tolerances, or print
25 5/3/2014 Contract Review/Product Realization Customer Cancels order
26 5/3/2014 Contract Review/Product Realization Customer provides fualty information
27 5/3/2014 Contract Review/Product Realization AIT communicates faulty information
28 5/3/2014 Vendor/Material Availability Using unapproved vendors
29 5/3/2014 Vendor/Material Availability Incorrect or incomplete purchase orders
30 5/3/2014 Vendor/Material Availability Material not to specification
31 5/3/2014 Vendor/Material Availability Material has no traceability
32 5/3/2014 Vendor/Material Availability Material is not available
33 5/3/2014 Product Realization Operator errors
34 5/3/2014 Product Realization Programming errors
35 5/17/2014 Vendor/Material Availability Vendor not available for repair/maintenance
36 5/17/2014 Vendor/Material Availability Tooling not available
37 5/17/2014 Vendor/Material Availability Stock or tooling back-ordered
38 5/23/2014 Contract Review/Product Realization Production schedule is backed up
39 6/2/2014 Software CMM has technical problem
40 6/2/2014 Software GibbsCAD has problem
41 6/2/2014 Software Server/computer crashes
42 6/2/2014 Key equipment MTE's inaccurate
43 7/11/2014 Software Server may overheat
44 7/11/2014 HSE Noise exposure
45 7/28/2014 Facility Vandalism of property
46 8/12/2014 HSE Exposure to smoke and hazardous fumes
47 8/22/2014 HSE Cuts, pinch points, and other hand injuries
48 9/10/2014 HSE Slip, Trip, Falls
49 9/11/2014 HSE Fall from heights
50 9/22/2014 Facility Theft of property
51 9/22/2014 Personnel Workplace violence/ harrassment
52 9/22/2014 Contract Review/Product Realization An entire order is scrapped due to an error

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

5/3/2014 1 Bodily Injuries Manufacturing shop contains multiple
(general) health, safety, & environmental hazards in
and around production areas. All facility
personnel and visitors are at risk upon
entering production areas
Industry - work performed is ALL Shop Severe Almost Certain Extreme: Substitution - change work practices, upgrade safety devices If injury does occur, the chart at the end of this document will be Everyone is responsible See PA and CA's written in Customer notification Moderate Likely High: submitted by Preston approved 5/3/2014 This serves as a blanket assessment
inherently dangerous Elimenation - completely followed to replace and/or redistribute responsibilites of injured person for safety. Preston, the last year. Monthly training required if delivery and/or by Jake of all bodily risk in a manufacturing
remove hazards with compentent personnel. When not forbidden by contract, Vendors Jake, Jason, Vincent and classes, Employee HSE quality will be affected, facility. Individual risk will be added
Engineering - modify work space and environment with from our AVL may be used to complete product realization. Chase are resposible for manual, and posted signs emergency response througout the year as we give
designated areas to contain each hazard supervions and training, discover a new risk, or
Adminstrative develop system and procedures enforcement develop better way to mitigate a risk
to control personnel interaction, identification, and awareness of
hazard PPE - require a
level of personal protective equipment when in production areas.

5/3/2014 2 Injury or damage to A nylon strap can break, All lifts with lifting Employees need further KeY Equipment, Shop Severe Likely Extreme: Elimination - damaged lifting devies will be removed, as well as We have multiple approved vendors who can supply new lifting devices Everyone is responsible See PA and CA's written in Customer notification Moderate Possible High: submitted by Preston approved 5/3/2014 Employees understanding necessity
equipment equipment can go wrong if weight isnt training and inspections need Personnel, handling of personnel not part of the lift anytime one needs replacement, repair lifting devices, and load test and for safety. Preston, the last year. Monthly training required if delivery and/or by Jake for inspecting slings, ratings, and
distributed evenly. enforcement product Sustitution - undamaged, higher rated lifting devices will certify lifting devices. If injury does occur, the chart at the end of this Jake, Jason, Vincent and classes, Employee HSE quality will be affected, center of gravity, along with not
replace any elimenatad document will be followed to replace and/or redistribute responsibilites Chase are resposible for manual, and posted signs emergency response having anyone or body part under a
Engineering - Lifting deviced are load tested, inspected, and of injured person with compentent personnel. When not forbidden by supervions and suspended load greatly lower risk
rated with capacity Administraton contract, Vendors from our AVL may be used to complete product enforcement
- safey classes will be given on use and inspection of lifting realization.
devices PPE - steel toe and safety
glasses required

5/3/2014 3 Release of Stored Shock or a mangled body - without having a Training and procedure Key Equipment, Facility Severe Possible Extreme: Elimination - Proper use of a LOTO proedure If injury does occur, the chart at the end of this document will be Maintenance manager, Training class, HSE safety Customer notification Severe Unlikely Extreme: submitted by Preston approved 5/3/2014 The potential release of hazardous
Energy lock out tag out procedure in place, serious lacked LOTO personnel Sustitution - Replacing defective items followed to replace and/or redistribute responsibilites of injured person shop foremen, and all manual, and posted signs required if delivery and/or by Jake energy will always remain a risk we
injury may occur while performing repair or Engineering - LOTO stations, orange with compentent personnel. When not forbidden by contract, Vendors employees quality will be affected, have to actively manage, especially
maintenance to equipment cones, caution tape, and other barricades from our AVL may be used to complete product realization. emergency response in instances where energy can't be
Administraton - provide training and awareness to all fully isolated for repair.
employees on LOTO PPE - Steel toe,
safety glasses, leather gloves

5/3/2014 4 Heat stress/ heat Dehydration, heat exhaustion, heat stress, Envirionment - the heat and Personnel Facility Severe Almost Certain Extreme: Engineering - Shaded areas, air Conditioning is provided If injury does occur, the chart at the end of this document will be Each employee is Hydration chart, heat stress Customer notification Moderate Possible High: submitted by Preston approved 5/3/2014 An estimation of over 90% of our
exhaustion heat fatigue humidity of our geography thorughout the shop, along with water followed to replace and/or redistribute responsibilites of injured person responsible for safety material, training class required if delivery and/or by Jake man hours are in a temperature
Administraton - Employees are reminded to stay hydrated with compentent personnel. In the event these controls prove to be monitoring his hydration quality will be affected, controlled environment. Extended
and given multiple breaks. Urine color charts are posted during inadequate or fail in some way, fans will be purchased, gatorade or level. Management will emergency response periods of labor perfomred outdoors
summer months. Personnel performing work outdoors are similar drinks that replinish essential salts will be purchased, and more provide knowledge and is sporadic, but needs to be monitored
required to take 15 minute breaks every hour. breaks will be given. relief in summer months.

5/3/2014 5 foreign particles in Foreign particles (grinding dust) can embed Grinding and cleaning with Personnel Shop Severe Likely Extreme: Engineering - guards on grinders, areas designated for If injury does occur, the chart at the end of this document will be Management is Training class, HSE safety Customer notification Moderate Possible High: submitted by Preston approved 5/3/2014 Enforcement of PPE is critical to
body in eyes, skin, be inhaled into lungs or compressed air. grinding, "safe zones", installation of mechanical ventilation followed to replace and/or redistribute responsibilites of injured person responsible for manual, and posted signs required if delivery and/or by Jake mitigate this risk. This is a risk that
ingested systems Administraton - HSE with compentent personnel. enforcing policy, every quality will be affected, is active every day, all day.
policy, PPE enforcement, good housekeeping required employee is responsible emergency response
PPE - safety glasses,goggles, face shields, dust for safety.
masks, gloves

5/3/2014 6 poison/ hazmat Hazardous chemicals can be inhaled, Hazardous chemicals exist Personnel Shop Severe Possible Extreme: Elimination - Selection of non hazardous substances If injury does occur, the chart at the end of this document will be Management is Training class, HSE safety Customer notification Major Rare High: submitted by Preston approved 5/3/2014 Employees need to be reminded to
ingested, or irritate skin through contact. throughout shop Substitution - Selection of less hazardous substances followed to replace and/or redistribute responsibilites of injured person responsible for manual, and posted signs, required if delivery and/or by Jake label open containers, to store
Engineering - Appropriate storage and segregation of with compentent personnel. enforcing policy, every quality will be affected, chemicals, and to follow procedure.
Dangerous Goods and Hazardous Substances (e.g. flame proof employee is responsible emergency response
cabinets or "paint lockers"), Installation of fire detection systems for safety.
(e.g. smoke detectors), Installation of fire fighting equipment
(e.g. fire extinguishers), Installation of chemical ventilation
systems
Administration "Right to Know" Material Safety Data Sheets
(MSDS) Station, Training for employees in the safe use and
handling of chemicals, Placarding of storage locations, Storage
of minimal quantities of chemicals, containers labeled, posted
Muster stations, Emergency evacuation drills
PPE - Provision of PPE, Provision ofSpill containment kits/skids

Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments
7/11/2014 44 Noise Permanent hearing losss may occur from Machinery and equipment is Compentent Personnel Shop Moderate Almost Certain Extreme: Engineering - Sound proofing/insulating of noisy areas If injury does occur, the chart at the end of this document will be QHSE Manager, Shop HSE Safety Manaul, safety Customer notification Insignificant Rare Low: submitted by Preston approved 7/11/2014 Simply, if the hearing protection
extended exposure to loud working loud - Insulation of equipment - Rubber matting or similar installed to followed to replace and/or redistribute responsibilites of injured person Forman class hand-outs, placards required if delivery and/or by Jake provided by AIT is used, hearing loss
environment dampen noise from moving parts vibration with compentent personnel. and signage quality will be affected, will not occur
Administration - Pre purchase assessment of equipment with emergency response
reference to the noise exposure standard- Equipment
maintenance schedule
PPE - Provision of PPE (e.g. hearing protection)

8/12/2014 46 Atmospheric Carcinogens may be inhaled due to exposure Employees smoke, canisters Compentent Personnel Shop Major Possible Extreme: Elimination - Smoking banned indoors If injury does occur, the chart at the end of this document will be QHSE Manager, Shop HSE Safety Manaul, safety Customer notification Minor Unlikely Low: submitted by Preston approved 8/12/2014 Smoking is prohibited indoors
contaminants to cigarrette smoke, hazardous fumes and containers leak Engineering - Installation of mechanical followed to replace and/or redistribute responsibilites of injured person Forman class hand-outs, placards required if delivery and/or by Jake
ventilation/extraction systems with compentent personnel. and signage quality will be affected,
Administration - Preventative maintenance program emergency response
- Appropriate storage and handling of Dangerous Goods and
Hazardous Substances
- Supervision of employees

8/22/2014 47 Hand Injury Personnel may injure hands from contact Sharp edges, hand placement Compentent Personnel Shop Major Possible Extreme: Substitution - The use tag lines when making lifts If injury does occur, the chart at the end of this document will be QHSE Manager, Shop HSE Safety Manaul, safety Customer notification Moderate Possible High: submitted by Preston approved 8/22/2014 Hand injuries account for the
with sharp surfaces, pinch points, and high Engineering - guards and doors exists on equipment and followed to replace and/or redistribute responsibilites of injured person Forman class hand-outs required if delivery and/or by Jake majority of injuries by a very large
temperatures machines, coolant is used while machine is cutting, abrasive with compentent personnel. quality will be affected, margin. 75% of industrial injuries
materials and grinders are used to remove sharp surfaces emergency response causing partial disability involve the
Administration - Safety class on hand safety, awareness hands.
promoted, implementation of safe work practices, work place
inspections, Supervision of Employees
PPE - gloves

9/10/2014 48 Slip, trips, fall Employees can slip, trip, and fall from Housekeeping Compentent Personnel Shop Major Likely Extreme: Elimination - Removal of trip hazards If injury does occur, the chart at the end of this document will be QHSE Manager, Shop HSE Safety Manaul, safety Customer notification Minor Possible Medium: submitted by Preston approved 9/10/2014 Good housekeeping must be enforced
hazards througout facility Engineering - Buildings constructed/designed to relevant followed to replace and/or redistribute responsibilites of injured Forman class hand-outs, placards required if delivery and/or by Jake
Standards and Building Code to ensure appropriate entry, person with compentent personnel. When not forbidden by and signage quality will be affected,
egress and storage areas, Provision of appropriate levels of contract, Vendors from our AVL may be used to complete product emergency response
lighting realization.
- Selection of hard wearing floor surfaces
- Non slip mats placed at the entrance to the building
- Installation of awnings over door entrances
Administration - Incident and hazard reporting
- Workplace inspections
- Preventative maintenance programs (e.g. cleaning and
repair/maintenance schedules)
- Training/education of employees
- Workplace uniform policy (e.g non slip footwear)

9/11/2014 49 fall from heights When peforming any work from an elevated Gravity Compentent Personnel Shop Severe Possible Extreme: Engineering - Use of elevated work platforms (e.g. man lifts), If injury does occur, the chart at the end of this document will be QHSE Manager, Shop HSE Safety Manaul, safety Customer notification Minor Possible Medium: submitted by Preston approved 9/11/2014 NOTE-- we must enforce this on 3rd
position (over 6'), employees may injure Installation of roof anchor points for work positioning/ fall followed to replace and/or redistribute responsibilites of injured Forman class hand-outs required if delivery and/or by Jake party personnel performing repairs as
themselves from fall arrest systems person with compentent personnel. When not forbidden by quality will be affected, well
Administration - Height safety training for employees contract, Vendors from our AVL may be used to complete product emergency response
Training in the use of step ladders (e.g. 3 points of contact), realization.
Use of industrial rated ladders
PPE - Provision and use of PPE (e.g. harness)

Process Impacted: Consequence Likelihood Risk Rating Elimination - Sustitution - Consequence Likelihood Risk Rating
Engineering -
Administraton - PPE -

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan

Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

5/3/2014 7 Power loss (external) Production comes to a halt due to loss of vary - power surges, weather, Key equipment, product Facility Moderate Almost Certain Extreme: Sustitution - use of generators and/or outsourcing work Suppliers/Vendors who can either provide us with generators or Operations Manager Approve Vendors List customer will require Minor Almost Certain High: Submitted by Preston, 5/3/2014
power for external reasons: e.g. - tree falling, car hitting power realization perform outsourced work (where not forbidden by contract) shall notification if delvery is Approved by Jake
transformer, power line, strom, general pole be added to our AVL to cover power loss for long periods of time. delayed, power company
power ottage
5/3/2014 8 Power loss (internal) Production comes to a halt do to a loss of overloading a circuit, an open Key equipment, product Facility Moderate Likely High: Sustitution - repair or replace suspect/damaged electrical Suppliers/Vendors who can either provide us with generators or Operations Manager Approve Vendors List, HSE customer will require Minor Possible Medium: Submitted by Preston, 5/3/2014
power for internal causes in the circuit, loose wiring realization components Engineering - utilizing perform outsourced work (where not forbidden by contract) shall Manual, LOTO Procedure, notification if delvery is Approved by Jake
a circuit rated one grade higner tha recommended (i.e.: a 30amp be added to our AVL to cover power loss for long periods of time. HSE walk-through inspection delayed
where a 20amp would be required) insulation of electrical wiring In addition, the co-owner is an electrical contractor with the form
(e.g. - conduit) Administration - resources and labor available to remedy any electrical problem
have employees trained in the usage of a lock out tag out
procedure, only certified employees allowed to perform repairs,
performance of preventative maintenance on all key equipment
and device PPE - use of leather gloves and rubber soled boots
when performing electrical repairs.

5/3/2014 9 fire Partial or total loss to facility, equipment, or vapors reaching ignition point Key equipment, product Facility Severe Possible Extreme: Elimination - Smoking and other sources of ignition are not AIT Machine is insured to cover (up to) total loss through fire. Shop Foreman Approve Vendors List, HSE customer will require Severe Unlikely Extreme: Submitted by Preston, 5/3/2014
server due to fire. with an ignition source realization allowed in shop Sustitution - Where not restricted by contract, vendors on our AVL may be used Operations Manager, Manual, fire extinguisher notification if delvery is Approved by Jake
present selection of less flammable substances to complete product while AIT recovers from consequences of any QHSE Manager inspection form, HSE walk- delayed, fire fighters
Engineering - proper storage of flammable materials in fire. Emergency preparedness plans are in place. through inspection form,
"paint locker", use of coolant, use of materials/infrastructure Posted placards, evacuation
that are flame retardant, installation of fire detection (smoke routes, muster stations
detectors), installation of fire fighting equipment, segregation of
flammable materials from possible ignition sources, designated
smoking area outdoors
Administraton - training of employees in safe work practices,
fire prevention, and fire safety, performing periodic inspections,
conducting fire drills, MSDS stations, placards used

5/3/2014 10 chemical spill The unathorized release (spill) of hazardous careless handling and or Personnel health, Facility Moderate Possible High: Elimination - Selection of non hazardous substances In the even chemical spill occurs, emergency preparedness plans Shop Foreman Approve Vendors List, HSE customer will require Moderate Unlikely Medium: Submitted by Preston, 5/3/2014
chemicals can result in unsafe work storage product realization Substitution - Selection of less hazardous substances are in place. If the spill results in inury to competent personnel, Operations Manager, Manual, fire extinguisher notification if delvery is Approved by Jake
conditions througout the facility. Engineering - Appropriate storage and segregation of other competent personnel will assume the duties of injured QHSE Manager inspection form, HSE walk- delayed, emergency
Dangerous Goods and Hazardous Substances (e.g. flame proof worker. In the event of catastrophic result, where not restricted by through inspection form, response & poison control
cabinets or "paint lockers"), Installation of fire detection systems our customer, product may be outsourced for completion to Posted placards, evacuation
(e.g. smoke detectors), Installation of fire fighting equipment vendors on our AVL routes, muster stations
(e.g. fire extinguishers), Installation of chemical ventilation
systems
Administration "Right to Know" Material Safety Data Sheets
(MSDS) Station, Training for employees in the safe use and
handling of chemicals, Placarding of storage locations, Storage
of minimal quantities of chemicals, containers labeled, posted
Muster stations, Emergency evacuation drills
PPE - Provision of PPE, Provision ofSpill containment kits/skids

7/28/2014 45 Vandalaism of Disgruntled employees or random Human nature key equipment, product Facility Minor Possible Medium: Engineering - Construction of buildings and structures with AIT will utilize Vendors/Suppliers listed on our Approved Vendors Operations Manager Employee Handbook, AVL, customer will require Insignificant Unlikely Low: Submitted by Preston, 7/28/2014
property delinquants vandalize company property realization, product robust materials that are difficult to damage and/or easy to repair List for the repair, replacement, and substitution of structure, SAF notification if delvery is Approved by Jake
(e.g.: company truck) delivery materials, or equipment which may incur vandalism or theft. delayed, police
Administration - Use of CCTV and other devices for
surveillance and observation
Facility 9/22/2014 50 Theft of company Disgruntled employees or random Human nature key equipment, product Facility Minor Possible Medium: Engineering - Construction of buildings and structures with AIT will utilize Vendors/Suppliers listed on our Approved Vendors Operations Manager Employee Handbook, AVL, customer will require Insignificant Unlikely Low: Submitted by Preston, 9/22/2014
and/or customer delinquants steal company and/or customer realization, product robust materials that are difficult to damage and/or easy to List for the repair, replacement, and substitution of structure, SAF notification if delvery is Approved by Jake
property property (e.g.: tooling, stock) delivery repair, appropriate storage and segregation of valuable materials, or equipment which may incur vandalism or theft. delayed, police
materials/supply
Administration - Use of CCTV and other devices for
surveillance and observation

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

5/3/2014 11 Sick, absent, Quality & Production suffers because an employee is Lack of planning Product realization, Facility Moderate Almost Certain Extreme Elimination - schedule vacations in advance so production The chart at the end of this document will be followed to replace and/or QHSE, HR, & Office Employee Manual, Work Customer notification Minor Almost Certain High Submitted by Preston, 5/3/2014
vacation sick, absent for other reasons, or on vacation. competent personnel schedule can be adusted accordingly redistribute responsibilites of sick/absent/separated personnel with Manager Instructions Manual, Job required if delivery and/or Approved by Jake
Sustitution - cross train designated employees so that compentent personnel. When not forbidden by contract, Vendors from Descriptions Manual, AIT quality will be affected
each position has a temporary substitute our AVL may be used to complete product realization. Training Form, Competence
Engineering - provision of mechanical ventilation, Evaluation Form,
vaccination programs (flu shots) Performance Management
Administraton - Infected employees to be referred for medical Evaluation Form
treatment/advice and remain at home until they are no longer
contagious - Provide employees with information on the signs
and symptoms of communicable diseases - Sanitation and
cleaning schedule - Workplace inspections

5/3/2014 12 employee Quality & Production suffers because an employee was Lack of planning, Product realization, Facility Moderate Almost Certain Extreme Sustitution - cross train designated employees for to provide The chart at the end of this document will be followed to replace and/or QHSE, HR, & Office Employee Manual, Work Customer notification Minor Almost Certain High Submitted by Preston, 5/3/2014
separation (fired fired or quit. shortage of good competent personnel temporary relief, utilize staffing services redistribute responsibilites of sick/absent/separated personnel with Manager Instructions Manual, Job required if delivery and/or Approved by Jake
or quit) help Engineering - develop contingency plan for specific compentent personnel. When not forbidden by contract, Vendors from Descriptions Manual, AIT quality will be affected
replacement of each key position and training programs our AVL may be used to complete product realization. Training Form, Competence
Administraton - continual assessment Evaluation Form,
of employee performance & competence, establishment of Performance Management
goals and providing tools and training necessary to reach those Evaluation Form
goals, clear communication and vehicles in place for continual
improvement and non conformance resolution

5/3/2014 13 employee Production & Quality suffer as a result of employee lack of training Product realization, Facility Major Almost Certain Extreme Elimination - Terminate all incompetent employees who show The chart at the end of this document will be followed to replace and/or QHSE, HR, Office, Employee Manual, Work Customer notification Major Possible Extreme Submitted by Preston, 5/3/2014
incompetence incompetence. competent personnel no improvement Sustitution - redistribute responsibilites of sick/absent/separated personnel with Operations, & Instructions Manual, Job required if delivery and/or Approved by Jake
hiring of only competent individuals, reassignment in job compentent personnel. When not forbidden by contract, Vendors from Manufacturing Descriptions Manual, AIT quality will be affected
responsibilities (an employee who is poor at operating a mill our AVL may be used to complete product realization. Managers Training Form, Competence
may be excellent as a shop hand) Evaluation Form,
Engineering - develop training programs and evaluation Performance Management
methods that identify the areas in need of improvement and the Evaluation Form
vehicle to advance Administraton
- employee training, assessment, supervision, & education,
utilization of specific work instructions

9/22/2014 51 Workplace Inappropriate behaviour, physical violence, verbal abuse, Human nature Product realization, Facility Moderate Possible High Engineering - Provision of CCTV/video surviellance The chart at the end of this document will be followed to replace and/or QHSE, HR, Office, Employee Manual, Work Customer notification Minor Possible Medium Submitted by Preston, 9/22/2014
violence threatening behaviour between employees effect the competent personnel Administraton - Sensitivity training, reporting redistribute responsibilites of sick/absent/separated personnel with Operations, & Instructions Manual, Job required if delivery and/or Approved by Jake
quality and speed of product realization of all incidents, indoctrination and training on acceptable compentent personnel. When not forbidden by contract, Vendors from Manufacturing Descriptions Manual, AIT quality will be affected
behavior and consequences for types of behavior deemed our AVL may be used to complete product realization. Managers, Shop Training Form, Competence
unacceptable (Employee code of condut), disciplinary Foreman Evaluation Form,
procedures Performance Management
Evaluation Form

Availability
of
Competent
Personnel

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

5/3/2014 14 crane failure Damage to equipment and product, injury to personnel structural damage, Key Equipment, Shop Severe Possible Extreme Substitution - use of forklift where applicable Jib crane - if the Jib crane is out of service, the overhead crane and Maintenance Manager, Preventative Maintenance Customer will need to be Moderate Unlikely Medium Submitted by Preston, 5/3/2014 Cranes are required to be inspected
may result from overhead & jib crane failure improper Personnel, Handling of Engineering - perform preventative forklift will be used. If the overhead crane is out of service and the jib Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake and certified by 3rd party annually.
maintenance product maintenance, inspections, display load capacities, instal anti- crane and forklift capacities are exceeded, AIT will rent lifting Operations manager, inspection, maintenance, or delivery date is to be
two block or limit switch equipment rated for the capacity needed until the overhead crane can be machine operators, repair & pre-use logs & forms, affected. If we are allowe to
Administraton - train employees on safe use and inspection repaired. Vendors will be chosen from AIT's AVL. QHSE Manager training class hand-outs, AIT use vendors, provide them
of, and preventative maintenance of, define and determine AVL, Work instructions with all specifications and
frequency of maintenance, supervise dangerous lifts, and teach manaul, job descriptions inspection criteria.
proper rigging/lifting techiniques manual
PPE - steel toe shoes, gloves, hard hat

5/3/2014 15 lifting device Damage to equipment and product, injury to personnel structural damage, Key Equipment, Shop Severe Possible Extreme Sustitution - usage of forklift or alternate or newer devices Lifting Devices (straps, slings, mangents, shackles, chains,ect) will be Maintenance Manager, Preventative Maintenance Customer will need to be Moderate Possible High Submitted by Preston, 5/3/2014 More training needs to be given on
failure may result from failure of lifting devices (straps, slings, improper Personnel, Handling of Egineering - perform immediately replaced from approved vendors. Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake proper use and inspection of
magnets, chains) maintenance product preventative maintenance, inspections, display load capacities Operations manager, inspection, maintenance, or delivery date is to be
Administraton - train machine operators, repair & pre-use logs & forms, affected. If we are allowe to
employees on safe use and inspection of, and preventative QHSE Manager training class hand-outs, AIT use vendors, provide them
maintenance of, define and determine frequency of AVL, Work instructions with all specifications and
maintenance, supervise dangerous lifts, and teach proper manaul, job descriptions inspection criteria.
rigging/lifting techiniques manual
PPE - steel toe shoes, gloves, hard hat

5/3/2014 16 forklift failure Damage to equipment and product, injury to personnel structural damage, Key Equipment, Facility Severe Possible Extreme Sustitution - use of cranes where applicable A replacement forklift will be rented through one of our approved Maintenance Manager, Preventative Maintenance Customer will need to be Minor Possible Medium Submitted by Preston, 5/3/2014
may result from forklift failure improper Personnel, Handling of Egineering - perform preventative vendors while our forklift undergoes repair. Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake
maintenance product maintenance, inspections, display load capacities Operations manager, inspection, maintenance, or delivery date is to be
Administraton - train employees on machine operators, repair & pre-use logs & forms, affected. If we are allowe to
safe use and inspection of, and preventative maintenance of, QHSE Manager training class hand-outs, AIT use vendors, provide them
define and determine frequency of maintenance, supervise AVL, Work instructions with all specifications and
dangerous lifts, and teach proper rigging/lifting techiniques manaul, job descriptions inspection criteria.
PPE - steel toe manual
shoes, gloves, hard hat

5/3/2014 17 company truck Damage to equipment and product, injury to personnel improper Key Equipment, Broussard Area Severe Possible Extreme Sustitution - contract 3rd party for shipping AIT will utilize 3rd party shipping services from approved vendors Maintenance Manager, Preventative Maintenance Customer will need to be Minor Possible Medium Submitted by Preston, 5/3/2014
failure may result from company truck failure maintenance Personnel, Handling of Engineering - perorm preventative (such as UPS freigt, Fed Ex) to pick up and deliver products and goods Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake
product maintenance, pre-use inspections, proper weight distribution, while company turck udnergoes repair or replacement. Operations manager, inspection, maintenance, or delivery date is to be
safe driving practices machine operators, repair & pre-use logs & forms, affected. If we are allowe to
Administraton - train employees on safe use and inspeciton QHSE Manager training class hand-outs, AIT use vendors, provide them
of, defensive driving, define and determine frequency of AVL, Work instructions with all specifications and
maintenance, have approved drivers list manaul, job descriptions inspection criteria.
PPE - DOT first aid kit, fire manual
extinguisher, seatbelt

5/3/2014 18 Horizontal mill Product can be damaged or delivery delayed due to improper Key Equipment, Handling Shop Major Possible Extreme Sustitution - outsource to vendors from our AVL where If the horizontal mill breaks to the point it will result in a very long Maintenance Manager, Preventative Maintenance Customer will need to be Moderate Possible High Submitted by Preston, 5/3/2014
breakdown failure or breakdown of horizontal mill maintenance, of product allowed in contract delay, the customer will be immediately notified to discuss how to Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake
incorrect tool path Engineering - perform preventative maintenance as proceed. When allowed, AIT will outsource the product to an approved Operations manager, inspection, maintenance, or delivery date is to be
recommended by OEM, maintain good housekeeping, inspect vendor with horizontal mill capabilities. machine operators, repair & pre-use logs & forms, affected. If we are allowe to
machine and area with regularity, chart tool path before QHSE Manager training class hand-outs, AIT use vendors, provide them
execution AVL, Work instructions with all specifications and
Administraton - train employees on safe use and inspection manaul, job descriptions inspection criteria.
of, and preventative maintenance of, define and determine manual
frequency of maintenance, procedure for ensuring program is
correct, require employees to be near machine during prove out
PPE - Steel
Toe shoe, safety glasses

5/3/2014 19 Regular mill Product can be damaged or delivery delayed due to improper Key Equipment, Handling Shop Moderate Possible High Sustitution - use other mill, outsource to vendors from our While a mill undergoes repair, other mills in the shop will be used to Maintenance Manager, Preventative Maintenance Customer will need to be Minor Possible Medium Submitted by Preston, 5/3/2014
breakdown failure or breakdown of cnc mills maintenance, of product AVL where allowed in contract complete work with the highest priority. If all jobs have equally high Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake
Key incorrect tool path Engineering - perform preventative maintenance as
recommended by OEM, maintain good housekeeping, inspect
priority, outsourcing work to approved vendors will be considered where
allowable by contract. If none of the orders alllow for outsourcing,
Operations manager,
machine operators,
inspection, maintenance,
repair & pre-use logs & forms,
or delivery date is to be
affected. If we are allowe to
Equipment machine and area with regularity, chart tool path before
execution
customers will be contacted for extensions or alternatives to proceed. QHSE Manager training class hand-outs, AIT
AVL, Work instructions
use vendors, provide them
with all specifications and
Administraton - train employees on safe use and inspection manaul, job descriptions inspection criteria.
of, and preventative maintenance of, define and determine manual
frequency of maintenance, procedure for ensuring program is
correct, require employees to be near machine during prove out
PPE - Steel
Toe shoe, safety glasses

5/3/2014 20 lathe breakdown Product can be damaged or delivery delayed due to improper Key Equipment, Shop Moderate Possible High Sustitution - outsource to vendors from our AVL where While a lathe undergoes repair, other lathes in the shop will be used to Maintenance Manager, Preventative Maintenance Customer will need to be Minor Possible Medium Submitted by Preston, 5/3/2014
failure or breakdown of cnc lathes maintenance, Handling of product allowed in contract complete work with the highest priority. If all jobs have equally high Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake
incorrect tool path Engineering - perform preventative maintenance as priority, outsourcing work to approved vendors will be considered where Operations manager, inspection, maintenance, or delivery date is to be
recommended by OEM, maintain good housekeeping, inspect allowable by contract. If none of the orders alllow for outsourcing, machine operators, repair & pre-use logs & forms, affected. If we are allowe to
machine and area with regularity, chart tool path before customers will be contacted for extensions or alternatives to proceed. QHSE Manager training class hand-outs, AIT use vendors, provide them
execution AVL, Work instructions with all specifications and
Administraton - train employees on safe use and inspection manaul, job descriptions inspection criteria.
of, and preventative maintenance of, define and determine manual
frequency of maintenance, procedure for ensuring program is
correct, require employees to be near machine during prove out
PPE - Steel
Toe shoe, safety glasses

5/3/2014 21 Saw breakdown Product can be damaged or delivery delayed due to improper Key Equipment, Handling Shop Moderate Possible High Sustitution - outsource to vendors from our AVL where In the event the Saw breaks, AIT will require its material providers Maintenance Manager, Preventative Maintenance Customer will need to be Minor Possible Medium Submitted by Preston, 5/3/2014
failure or breakdown of saw maintenance of product allowed in contract (approved vendor) to saw cut stock material prior to delivery until the Shop Hand, Mfg & Procedure, Daily & monthly notified in the event quality Approved by Jake
Engineering - perform preventative maintenance as Saw is repaired or replaced. Operations manager, inspection, maintenance, or delivery date is to be
recommended by OEM, maintain good housekeeping, inspect machine operators, repair & pre-use logs & forms, affected. If we are allowe to
machine and area with regularity QHSE Manager training class hand-outs, AIT use vendors, provide them
Administraton - train employees on safe use and AVL, Work instructions with all specifications and
inspection of, and preventative maintenance of, define and manaul, job descriptions inspection criteria.
determine frequency of maintenance, require employees to manual
remain near during use
PPE - Steel Toe shoe, safety glasses

6/2/2014 42 MTE's Product can mistakenly be machined to incorrect Verification and/or Key Equipment, Shop, Quality Major Likely Extreme Substitution - utilize a minimum of two separate MTE's when In order to catch this problem, AIT Machine verifies MTE's on a daily Maintenance Manager, Preventative Maintenance The customer will need to Moderate Possible High Submitted by Preston, 6/2/2014 Operators need to document their
inaccurate specification if MTE's aren't accurate calibration Personnel, Handling of Dept. possible during final inspection basis. AIT also utilizes separate MTE's for final inspection than those Shop Hand, Mfg & Procedure, Daily & monthly be notified in the event MTE Approved by Jake MTE verification logs!!
frequency not product used during product realization. Measurements during realization are Operations manager, inspection, maintenance, failure is discovered.
requent enough Engineering - have at least two of every MTE, Verify and recorded, then validated during final inspection. For the few MTE's AIT machine operators, repair & pre-use logs & forms,
Calibrate MTE's, keep MTE's properly stored and maintained, does not have multiple of (go & no-go gages), the s/n's are recorded of QHSE Manager training class hand-outs, AIT
assign a traceable # to every MTE, record MTE usage on all MTE's used during final inspection. If MTE failure occurs and AVL, Work instructions
inspection reports somehow slips through all the layers we have in place, an investigation manaul, job descriptions
Administraton - define calibration schedule, procedures, and will occur to determine if other product validated with failed MTE's manual
frequency, train and qualify competent individuals to verify or requires recall.
calibrate MTE's, assess and qualify accredited vendors for
calibration, require operators do verify and document MTE's,
supervise and teach proper techiniques for using MTEs

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence

5/3/2014 22 Change in scope Customer requests changes of scope or specification to Customer's Product realization, on All Major Likely Extreme Engineering - MOC and a risk analysis will be performed
the contract/purchase order and product during perogative time delivery prior to implementation; The product/proccess must be
realization, potentially causing in-process order to be stopped immediately to determine where in realization the
delayed or scrapped product is assess viability of change. Administartion -
Train employees to MOC procedures, provision for MOC
& traceability,

5/3/2014 23 unfamiliar Customer requires a process or procedure we are not Inexperience Product realization, on All Moderate Possible High Elimination - receive training on all industry standards
requirement familiar or have very little experience executing, causing time delivery Sustitution - customer
product completion to be delayed or scrapped guidlines and specifications, extra material is ordered as a
"set-up" piece
Engineering - dwg or print includeds requirements and
notes. Program includes set-up or startup instructions.
first article and in-process inspections
Administraton - Training is provided to all
affected employees, routers and hold/inspection points
utilized

5/3/2014 24 insufficient Customer does not provide specifications, tolerances, or Customer Product realization, on All Severe Likely Extreme Elimination - request clarification.
specification drawings/print, allowing for product to be made to the Inexperience time delivery Sustitution - clarify for the customer and
wrong specifications have them siang and date clarifications during contract
review. Engineering -
process such as contract review included in the QMS to
provide instruction in this matter
Administraton - affected personnel trainied to
our policy and procedure for obtaining clarification and
narrowing interpretations, defining exactly what it is the
5/3/2014 25 order cancelled Customer cancels order during realization, causing an Customer's Product realization, on All Severe Likely Extreme Elimination
customer wants-
enormous waste of resource perogative time delivery Sustitution -
Engineering -
Administraton -
PPE -

5/3/2014 26 Faulty Info Customer provided AIT Machine with faulty information Customer's mistake Product realization, on All Severe Likely Extreme Elimination -
or fails to communicate a requirement to AIT Machine, time delivery Sustitution -
causing product to require rework or scrap Engineering -
Administraton -
PPE -

5/3/2014 27 Faulty Info AIT Machine provides or communicates faulty Training Product realization, on All Severe Likely Extreme Elimination -
information to its customers or vendors or personnel, time delivery Sustitution -
Contract resulting in product rework or scrap Engineering -
Administraton -
Review PPE -

5/23/2014 38 Backlog Production is behind schedule, causing a severe back-log shortage of Product realization, on All Major Likely Extreme Elimination -
competent personnel time delivery Sustitution -
Engineering -
Administraton -
PPE -

9/22/2014 52 order Srapped A big mistake is made and an entire order is scrapped. procedure not Product realization, on All Severe Likely Extreme Elimination -
followed time delivery Sustitution -
Engineering -
Administraton -
PPE -

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Residual Risk

Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence

Supplier
Performance
& Material
Availability

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Residual Risk

Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence

Product
Realization

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Residual Risk

Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence

Delivery of
Non-
Conforming
Product

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Residual Risk

Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Inherent Risk Residual Risk

Date: Risk # Type of Risk Risk Scenario Root Cause Process Impacted: Locations Consequence Likelihood Risk Rating Risk Treatment Contingency Plan Responsible Person(s) Internal Communications External Communications Consequence

Weather

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014

 AIT Machine Risk Assessment, Mitigation, Contingency Plan
Residual Risk

Likelihood Risk Rating Submitted To / Approved By: Implementation Date Comments

Approved by: Controlled Document AITM-058, Rev. 1 - 05/03/2014