Unit IG2: Risk assessment

Declaration: By submitting this assessment (Parts 1 – 4) for marking I declare that it is entirely my own work. I understand that falsely claiming that
the work is my own is malpractice and can lead to NEBOSH imposing severe penalties (see the NEBOSH Malpractice Policy for further information).

Important note: You must refer to the document ‘Unit IG2: risk assessment – Guidance and information for learners and Learning Partners’ while
completing all parts of this assessment. Your Learning Partner should provide you with a copy, but it can also be downloaded from the relevant
resources section for this qualification on the NEBOSH website.

Part 1: Background

You should aim to complete this section in 150 - 200 words.

Topic Comments
Name of organisation* Atlas plastic moulding company
Site location* Plot XX, Sector yy, Site, Karachi Pakistan
Number of workers 45
General description of the organisation The company manufactures medical devices including bottles spoons’ and caps for global
pharmaceutical brands. The company has a CEO, Factor Manager, Accounts Manager,
Production Supervisor, Quality supervisor, QC inspectors, machine operators, helpers, and
maintenance supervisor, electrician. The workforce employed is within an age bracket of 25 to
55yrs.
The company is spread over an area of 1000m 2. The processes carried out at the plant are
storage of plastic resins, plastic injection and blow moulding of plastic resin, checking, packing
and delivery. The company has 2 washrooms and a canteen facility. The plastic injection
moulding department has a large worker changing room with partial space utilization containing
wooden cupboards, storage boxes for masks, gloves, and hairnets. There is a mould storage area
and a space for keeping polypropylene plastic resin. There are 4 old / refurbished injection
moulding machines installed parallel to each other with a distance of approximately 4m and
workers were seen operating machines and equipment in a workshop attire in extreme
temperature. The unfinished goods are kept in polybags near the machines. The process raw
material is manually picked and loaded in the hopper. Inadequately maintained production floor.
There is a small passage to transport the goods to the finishing section. Adjacent to it is the

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 packing area and delivery passage. The production area does not have a provision of emergency
exit with one exhaust mounted in one of the windows. Worn out electrical switchboards, oil
leakage near machines, poor housekeeping, inadequate lighting, inadequate ventilation & work
equipment safety issues were significant.
On the day of my visit to the plant I observed covid’19 precautions clearly displayed at the
entrance and a delivery van carrying resin was being offloaded.
The company works in three shifts 8hrs each from 8:00am to 4:00pm, 4:00pm to12:00am and
then from 12:00am to 8:00am 6 days a week with Sunday as an off day.

The assessment was carried out on 5th May 2021

Description of the area to be included in the
The area selected for the risk assessment is the plastic injection moulding department.
risk assessment
The factory manager has the responsibility of the health and safety matters and reports
Any other relevant information
directly to the CEO.
* If you’re worried about confidentiality, you can invent a false name and location for your organisation but, all other information provided must be
factual.

You should aim to complete this section in 100 - 200 words.

Note: this section can be completed after you have competed your risk assessment.
Outline how the risk assessment was
carried out this should include:
 sources of information consulted;
 who you spoke to; and
 how you identified:
- the hazards;
- what is already being done; and
- any additional controls/actions
that may be required.

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 Part 2: Risk Assessment

Organisation name: Atlas plastic moulding company

Date of assessment: 5th May 2021
Scope of risk assessment: The area selected for the risk assessment is the Plastic injection moulding department.

Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
Health, Welfare Workers using the change Instructions on using the change 1. One tier cupboards of size 1. 4 week 1. Accounts
& Work room. room were clearly displayed in 12”x18”x72”, 45 in total made up of 2. 1 day Manager
Environment English and Urdu. stainless steel. 2. Factory
No provision of keeping away 2. Instructions on work attire should be Manager
heavily soiled, stained and or Safety Instructions on covid’19 were clearly displayed in the change
Inadequate
impregnated workshop attire clearly displayed in Urdu. room.
Accommodation for
from the street clothes would 3. All lockers should have a provision
Clothing
increase chances of PPEs including face masks, of lock, key and name tag.
contamination. hairnets, and gloves were provided
The workers were
and stored in separate bins.
keeping their
Without locks, chances of theft
belongings
and misuse of personal Dust bins were provided for dumping
including street
belongings would lead to used PPEs.
clothes in wooden
mental stress and work related
cupboards which
violence. .
were insufficient,
without separation
and without locks.
Workers using the change Lighting fixtures of very low intensity 1. Purchase light intensity meter 1. 1 week 1. Accounts
room and Production Area were in use. 2. Replace all lighting fixtures with 2. 2 days Manager
Lighting Lighting fixtures were not shatter 20w LEDs with covering. 3. 1 hr 2. Maintenance
The worker in the Poor lighting will cause proof. 3. Replace LEDs which flicker and 4. I day Supervisor
production facility difficulty in movement, visibility cast a shadow. 3. Maintenance
were subject to and prolong use shall cause 4. Instructions on use and Supervisor
insufficient lighting. visual discomfort. replacement of lights to be 4. Factory
displayed in the production area. Manager

Workers using the change A small bracket fan is installed in 1. Procurement of HEPA Filters, 1. 4 weeks 1. Accounts
Ventilation room the change room area. Air conditioners, bracket fans, 2. 2 weeks Manager

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Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
and exhaust fans 3. 2 days 2. Maintenance
There was no 2. Installation of HEPA filters, Air 4. 1 week Supervisor
provision given for Poor ventilation will cause Conditioner, Exhaust fan, 3. Factory
circulation of fresh suffocation due to the sweat bracket fans at least 4. Manager
air with in the and any other obnoxious smell 4. Factory
change room and coming with the working attire.
3. Instructions on use of Manager
Production area. appliances to be displayed.
4. Training on cleaning of HEPA
Filters
Workers using the change Waste Packing material is kept in 1. Remove the waste from the change 1. 4 weeks 1. Janitor
Inadequate area/ room and Production Area one corner of the room without room and keep in a separate area 2. 2 weeks 2. Maintenance
Space proper stacking. 2. Isolate the waste material by 3. 1 day Supervisor
Inadequate utilization of space barricading or putting in a cage. 4. 1 week 3. Factory
in the change room will cause 3. Clear identification of the waste Manager
Waste kept in the 5. 1 day
difficulty in movement and material. 4. Maintenance
change room
poor management of workers 4. Floor marking for Clear Supervisor
causing difficulty in
belongings. identification of the physical hazard. 5. Factory
worker movement.
5. develop and implement Waste Manager
disposal procedure 6. Factory
6. Communicating the hazard to the Manager
workers.
Workers using the change 1. Training provided to the 1. Purchase dedicated footwear in the 1. 1 week 1. Accounts
Improper room and Production Area janitors. production area. 2. 2 weeks Manager
Cleaning 2. Records of cleaning 2. Install eyewash units in the 3. Daily 2. Maintenance
Inadequate cleaning maintained. production area. 4. 3 months Supervisor
procedure would create 3. Regular cleaning and mopping of 5. Daily 3. Janitor
Sand Dirt, Dust on
possible chances of cross the floor and walls. 6. Daily 4. Janitor
floor and oily hand
contamination and infection 4. Regular fumigation to disinfect the 7. 1 week 5. Operators
marks on walls in
posing significant impact on change room and production area. 8. Daily 6. Operators
the change room
the worker’s health and 5. Periodic inspection of machines to 7. Factory
and production
passing on the contaminants check for oil leaks. Manager
area were
esp. oil and dust to the 6. Use of waste cotton for cleaning of 8. Operators
prominent
production area. . oil stains by the workers.
7. Training to the workers and display
It would also give a poor of cleaning instructions in native
aesthetic look to the changing language.
facility. 8. Use of cotton gloves & goggles
Operators, Supervisors and 1. Cotton pants and half 1. Procurement and Installation of air 1. 4 weeks 1. Accounts
Exposure to Helpers working in close sleeves T shirts are conditioning, exhaust and fans to 2. 4 weeks Manager

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Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
Extreme proximity to the moulding provided. provide moving air (which has a 3. 4 weeks and
temperature machines 2. A large industrial fan is cooling effect). 4. 4 weeks Maintenance
installed in the production 2. Insulation of heat sources by lagging 5. 1 week Supervisor
Workers exposed As the moulding process area. hot pipes and injection sleeves. 6. 1 week 2. Maintenance
to high involves melting of the plastic 3. Shield heat sources to control radiant 7. 4 weeks Supervisor
temperature near resin at unbearably high heat and prevent contact burns. 8. 1 week 3. Maintenance
temperatures between 140 to 4. Provide cool refuges where workers Supervisor
the machines. 150oC the surrounding air can escape the heat. 4.
temperature becomes high 5. Provide easy access to drinking water
especially in the summer or isotonic drinks (which replace salts
season becoming unbearable lost through sweating).
for the operators. This would 6. Provide frequent breaks and job
cause Dehydration, Muscle rotation.
cramps, Heat stress and Heat 7. Provide 100% cotton clothing that
exhaustion. allows workers to sweat freely.
8. Training to the workers on how to take
preventive measures against the heat
Slips and Trips Operators, Supervisors and 1. Cleaning instructions 1. Procurement and Application of non-slip 1. 4 weeks 1. Accounts
Helpers displayed in the production resin on the slippery surface. 2. 4 weeks Manager and
area. 2. Repair uneven floor 3. 1 week supplier
3. Allocate area away from the machine 2. Mason
Slipping and Oily floor due to oil leakage 2. General safety instructions 4. 2 weeks
and walkway for stacking of unfinished 3. Factory
from machines would cause related to floor plastic parts 5. 2 weeks Manager
Tripping management were 6. 1 week
the workers to slip 4. Install Racks and pallets for keeping 4. Maintenance
inadvertently. Also uneven displayed. plastic items. 7. 1 week Supervisor
Workers may slip 5. Use appropriate slip resistant footwear. 8. 1 week 5. Workers
and broken floor and Plastic
or trip during 6. Awareness on Prohibition of high healed 9. Monthly 6. Factory
parts lying on floor near the
movement in the and fancy shoes 10. Daily Manager
machines in polybags will
workplace. 7. Display safety instructions and signs on 11. Daily 7. Factory
pose significant impact on the
the use of footwear. Manager
worker’s movement leading to 12. Daily
8. Provide training to the staff at the time of 8. Factory
broken bones especially on induction and during job. Manager
the head, arms, wrist 9. Periodic maintenance of machines. 9. Maintenance
10. Cleaning of machines Supervisor
11. Cleaning of the premises 10. Operators
12. Supervision at work 11. Janitor
12. Production
Supervisor

Work Operators, Supervisors and 1. Warning Signs were 1. Procurement and Installation of 1. 8 weeks 1. Accounts
Equipment Helpers displayed near the mould interlocked guards. 2. 4 weeks Manager &

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Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
section of the machine. 2. Install a sliding gate with push- 3. 1 week Maintenance
Operator is No guarding systems installed 2. Trained and Authorized sticks and holders. 4. 2 weeks Supervisor
exposed to the in the mould section and the worker was operating the 3. Display safety instructions and 2. Maintenance
mould section of operators were directly machine. warning signs near the machine Supervisor
the machine exposed to the heat and 4. Availability of machine manuals 3. Factory
without any access flashes (residual molten Manager
control feature plastic) to cause severe skin 4. Factory
burns and rashes.. It could Manager
also severely cause fingers
and wrist injury during ejection
of parts.
Operators, Supervisors and 1. Markings on 1. Colour code all pipes of water inlet 1. 4 weeks 1. Maintenance
Water pipes, Helpers EMERGENCY, STOP and and outlet, air pipes from 2. 4 weeks Supervisor
hydraulic pipes and START control were done. compressors, hydraulic oil pipes 3. 1 week 2. Maintenance
electrical Without appropriate marking and electric cables and boards. 4. 1 week Supervisor
equipment/cables likelihood of mishandling of 2. Label with flow direction 3. Factory
were not marked equipment and use of 3. Display safety instructions near the Manager
inappropriate tools becomes machine defining the colour codes. 4. Factory
high and chances of injuries 4. Supervision Manager
are predominant including 5. Train the workers and staff on 5. Factory
electric shock, body burns due colour code std. Manager
to exposure to hot fluid.
Maintenance Workers Authorized Person was carrying out 1. Power sources should be isolated and 1. 1hr 1. Maintenance
Maintenance work the task physically locked off (secured) Supervisor
2. 15 min
2. Stored power should be released or 2. Maintenance
on one machine’s This would put the 3. 1hr
secured to prevent accidental discharge. Supervisor
mould clamp unit maintenance worker directly in 3. Fit maintenance guards that have been 6. 1 week 3. Maintenance
was carried out by harm’s way as the machine made specifically to allow minimum Supervisor
disengaging the could reenergize and or access to required areas only. 4. Maintenance
safety device. accidently switched on by the 4. Adequate supervision Supervisor
operator leading to severe 5. Use of appropriate tools 5. Maintenance
hand, wrist and arm injuries. 6. Training to the maintenance workers Supervisor
7. Use of lockout and tag out procedure 6. Factory
8. Use of appropriate gloves. Manager
7. Factory
Manager
8. workers
Noise Operators, Supervisors and 1. Ear plugs are provided. 1. Noise Risk Assessment with a 1. 3 days 1. Factory
Helpers 2. Training on use of ear noise meter. 2. 4 weeks Manager
2. Replace plunger bearings, injector 3. 12 months 2. Maintenance
Loud impulsive plugs is given.

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Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
sound produced The sound generated from the pins, pressure release valves, oiling 4. 2 months Supervisor
from the impact of plunger impact with the mould greasing, 5. 6 months 3. CEO
the plunger body is intense and impulsive 3. Replace old machines with new and 6. Monthly 4. Maintenance
7. Daily Supervisor
and may lead to muffed efficient ones.
8. Daily 5. Accounts
hearing, temporary threshold 4. Build acoustic enclosure around the 9. Monthly Manager,
shift, and inability to hear noise source. 10. 1 week painter
instructions. It also causes 5. Use of sound absorbing material on 11. 6 monthly 6. Maintenance
stress effect. walls. Supervisor
6. Routine inspection of machines 7. Factory
7. Provide ear muffs. Manager
8. Supervision on use of ear muffs 8. Factory
Manager,
9. Training to the workers on use of
production
PPEs. supervisors
10. Display of safety instructions and 9. Factory
safety signs near the machines. Manager
11. Medical tests such audiometry. 10. Factory
Manager
Manual Handing Helpers 1. A four step foot board is 1. Conduct risk assessment using TILE 1. 1 week 1. Factory
provided. method. 2. 4 weeks Manager
2. Use of electric pallet trucks for moving 3. 3 months 2. Accounts
Worker performing The helpers carry the 25kg
plastic bags near the machine 4. 1 week manager &
Manual Loading of bag on their back or close to 3. Installation of a pneumatic system for 5. 1 week Production
25kg plastic resin the torso moving at least 20 ft. transfer of plastic resin from the 6. 1 week Supervisor
bag into the The strain could lead to container to the hopper. 7. 1 day 3. Maintenance
hopper musculoskeletal disorders 4. Repair and maintain even flooring 8. 1 week Supervisor
such as Back injuries, Work- 5. Control repetitive handling by 4. Maintenance
related upper limb disorders. introducing frequent rest breaks or job Supervisor
Muscle tears/strains Tendon rotation to minimise the length of time 5. Factory
that an individual worker has to perform Manager
and ligament
the task. 6. Factory
injuries/tears/strains. Hernias. 6. Develop safe system of work including Manager
Cuts, burns, dislocation and a. Use a table or lift to bring the load to 7. Factory
broken bones. waist height to eliminate picking up from Manager
floor level. 8. Factory
b. use several workers to handle a large, Manager
bulky load rather than just one.
c. Stabilise an unstable load by securing it
or putting it into a container.
d. Mark up a load with an off-centre centre
of gravity so that workers can see where
the centre of gravity is.

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Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
e. Supply additional lighting in a poorly lit
location.
7. Display of safety signs, instructions and
training on good handling techniques.
8. Use of gloves to prevent cuts.
Hazardous Operators, Supervisors and 1. Warning Signs 1. Carry out air quality test 1. 1 week 1. Factory
Helpers 2. Safety Instruction 2. Procure and install appropriate 2. 4 weeks Manager
Substance
3. Masks fume extraction unit. 3. Daily 2. Accounts
Manager and
Workers exposed Fumes may contain acetone and 3. Always use food grade resin 4. 1 week
Maintenance
or acrolein. Exposure will cause 4. Display safety instructions and 5. Daily
to fumes resulting Supervisor
irritation to eyes, skin, mucus signs and MSDS 6. Monthly
from the plastic 3. Factory
membrane, nose, throat, 5. Proper supervision 7. quarterly
resin melting Manager
dermatitis, dizziness, chronic
process 6. Regular inspection and cleaning of 8. 2 weeks 4. Factory
respiratory diseases and
extraction system 9. Monthly Manager
decreased pulmonary function.
7. Periodic air quality monitoring 10. Daily 5. Factory
8. Develop safe system of work Manager and
Production
9. Training to the workers
Supervisor
10. Use of Filtering face-piece 6. Factory
respirator Manager and
Maintenance
Supervisor
7. Factory
Manager
8. Factory
Manager
9. Factory
Manager
10. Factory
Manager
Fire Operators, Supervisors and 1. No Smoking Warning Signs 1. Remove the resin from the 1. 1 day 19. Supervisor
Helpers 2. CO2 Fire Extinguisher production work place. 2. 4 weeks 20. Accounts
2. Construction of a passage with 3. 4 weeks Manager and
Polypropylene 4. 4 weeks Maintenance
resin was stored in A small quantity of the resin easy access to the production area
5. 4 weeks Supervisor
the production area was placed some 20ft from the for movement of the raw material. 6. 2 weeks 21. Factory
in open space. machines in open space. High 3. Proper ventilation system to be in 7. 1 week Manager
ambient temperature place 8. 1 week 22. Factory
especially in summer season 4. Installation of fire alarms, manual 9. 1 week Manager
could trigger fire. call points, smoke detectors 10. 1 week 23. Factory
5. Maintain room temperature <30oC 11. 2 weeks Manager
6. Use shatter proof lights 12. Daily 24. Factory

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Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
7. Do not keep any other flammable 13. Monthly Manager
items in the resin area or close to it. 14. Daily 25. Factory
8. Keep the resin in an enclosure 15. 1 week Manager
16. Daily 26. Factory
9. Put hazardous substance (COSHH)
17. monthly Manager
identification tag on the enclosure 18. 1 week 27. CEO
and on every bag of resin. 28. Factory
10. Display workplace hazard Manager
information near the storage area. 29. Maintenance
11. Provide security near storage to Supervisor
avoid deliberate ignition 30. Factory
12. Maintain clean environment Manager
31. Factory
13. Maintain good electrical
Manager
connections 32. Factory
14. Proper supervision Manager
15. Develop SSW through PTW. 33. Factory
16. Periodic monitoring of the Manager
temperature 34. Factory
17. Training on use of PPE Manager
18. fire blankets 35. Factory
Manager

Electrical Fire Operators, Supervisors and 1. Display of electrical hazard 1. Replace all worn out and poor 1. 2 weeks 1. Maintenance
-Poor and worn out Helpers signs. quality sockets, switches, cables 2. 1 week Supervisor
electrical and Accounts
2. CO2 Fire Extinguisher and wires with good quality CE 3. 1 week
Manager
connections and Worn out plugs, wires, lack of marked equipment. 4. 1 week
2. Maintenance
wires. inspection and inadequate 2. Installation of fuses and MCBs. 5. Monthly Supervisor
ventilation will cause 3. Proper marking of electrical 6. Monthly 3. Factory
overheating and would initiate connections. 7. 1 week Manager
fire especially near the electric 4. Proper electrical hazard 8. 1 week 4. Factory
heater area of the machine. identification 9. Monthly Manager
Workers near the machines 5. Routine inspection by competent 10. 1 week 5. Electric
person technician
will suffer burns.
6. Maintenance
6. Routine maintenance of equipment
Supervisor
7. Display of safety instructions, signs 7. Factory
8. Develop safe system of work Manager
9. Impart training to the workers 8. Factory
10. Install CO2 or dry powder fire Manager
extinguishers 9. Factory
Manager

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Hazard Who might be harmed What are you already What further controls/actions are Timescales for
category and and how? doing? required? further actions Responsible
hazard to be person’s job
completed title
(within …)
10. Factory
Manager
Operators, Supervisors and 1. Exit printed sign boards 1. Conduct fire risk assessment 1. 1 week 1. Factory
There was no Helpers 2. Select for Two or more separate 2. 1 week Manager,
means of escape escape routes should be provided 3. 4 weeks 2. Factory
4. 4 weeks Manager
from the production In case of fire the workers will so that if one route is blocked, there
5. 4 weeks 3. Maintenance
area in case of fire. have only once access point i- is another available. 6. Monthly Supervisor
e the main entrance and no 3. Installation of Fire Resistant doors. 7. 1 week 4. Maintenance
other point which drastically 4. Installation of emergency lighting 8. 1 week supervisor
increase the likelihood of 5. Installation of photoluminescent exit 9. 1 week 5. Maintenance
entrapment leading to and escape signs. 10. monthly supervisor
suffocation, severe burns and 6. Periodic inspection of the escape 6. Factory
routes and signs Manager
even death.
7. Factory
7. Develop emergency evacuation
Manager
procedure 8. Factory
8. Selection and training of fire Manager
marshals. 9. Factory
9. Develop fire plans Manager
10. Conduct regular fire drills 10. Factory
Manager

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Part 3: Prioritise 3 actions with justification for the selection
Suggested word counts
Moral and financial arguments for all actions: 300 to 350 words
For EACH action:
Specific legal arguments: 100 to 150 words
Likelihood AND severity: 75 to 150 words
How effective the action is likely to be in controlling the risk: 100 to 150 words

Moral and financial arguments for ALL actions

Moral, general legal and financial
arguments

Justification for action 1

Action

Specific legal arguments

Consideration of likelihood AND severity

How effective the action is likely to be in
controlling the risk. This should include:
 the intended impact of the action;
 justification for the timescale that you
indicated in your risk assessment;
and
 whether you think the action will fully
control the risk.

Justification for action 2

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 Action

Specific legal arguments

Consideration of likelihood AND severity

How effective the action is likely to be in
controlling the risk. This should include:
 the intended impact of the action;
 justification for the timescale that you
indicated in your risk assessment;
and
 whether you think the action will fully
control the risk.

Justification for action 3

Action

Specific legal arguments

Consideration of likelihood AND severity

How effective the action is likely to be in
controlling the risk. This should include:
 the intended impact of the action;
 justification for the timescale that you
indicated in your risk assessment;
and
 whether you think the action will fully
control the risk.

Part 4: Review, communicate and check

Suggested word counts for each section:
 Planned review date or period and reasoning for this: 50 - 100 words

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  How the risk assessment findings will be communicated and who needs to know the information: 100 - 150 words
 Follow up on the risk assessment: 100 - 150 words.

Planned review date/period with

reasoning
How the risk assessment findings will be
communicated AND who you need to tell
How you will follow up on the risk
assessment to check that the actions
have been carried out

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