Scope: Old & New Packing Hall Department / Plant: Ef&P Review Date

ABBREVIATIO
NS:
N - Normal
A – Abnormal
E – Emergency
S – Severity
P – Probability
L – Legislation
F - Frequency
DEPARTMENT \ PLANT: EF&P
Review date: 25.08.2011
Scope: Old & New Packing Hall
Hazard Category / Aspect

Define Process/ Activity
No. of People Exposed
Relevant Legislation
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
SAFETY
EFP001 Fixing leaks or reparing Working at Heights Slipping and falling X N <10m only done 1 Ladder register – checklist. None OHS 85 0f 1993 Sec 8 3 4 0 5 35 40
ONPHS pipes,changing lights from above, Injury when there ia a Site rules.
using a ladder or fatality need Ladders are inspected before use.
Working according
to Unilever working @ heights
standards, safety harness GSR Sec 6,13
EFP002 Erecting of Scaffolding Working at Heights Improper erection X A < 10m.Only 5 Training in use of equipment, only None OHS 85 0f 1993 Sec 8 7 4 0 4 44 55
ONPHS by Contractors of scaffold may done when use reputable company,
cause people to fall there is a need. construction regs. CR Sec 8
off scaffold to Working according to Unilever
collapse leading to working@ heights standards.
serious injuries or GSR Sec 6,13
fatality
EFP003 Performing any work at Working at Heights people not X A < 10m.Only 5 Work Permits, working at heights None OHS 85 7,8,14,15
CR Sec 0f 1993 Sec 8 7 5 0 4 48 52
ONPHS Heights (General) adhering to done when permit, inductions, project
working @ heights there is a need. supervisors
instructions leading
to accidents,
serious injury or GSR Sec 6,13
fatality
EFP004 Performing any work at Working at Heights Potential for injury X N < 10m.Only 5 Only reputable scaffolding None OHS 85 0f 1993 Sec 8 3 3 0 5 30 30
ONPHS Heights (General) due to damaged done when company utiliised, project
equipment being there is a need. supervisors, Workpermit, & CR Sec 7,8,14,15
used Inspection of eqiupment before is
(scaffold/ladders) used
GSR Sec 6,13
EFP005 Moving packaging Unstable loads falling off May cause injuries X N 500kg.Daily 1 Awareness, Training, SOP None OHS 85 7,8,14,15
CR Sec 0f 1993 Sec 8 & 3 3 0 10 60 60 (T)
ONPHS material around the floor if it falls to people exposure 7.5.14.8.Safe stacking practise 14
using a powered pallet nearby, fatality or
truck property and
product damage.
GSR Sec 8
Page 1 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
Near Miss Hit by a Pallet Jack Pallet Jack Feet Injury
EFP006 Changing of light bulbs Bulbs getting Cuts to hands or X N 100 globes and 3 Informal training for person fitting None OHS 85 0f 1993 Sec 8 2 5 0 5 35 54
ONPHS by Electrical Contractor broken/damaged during even glass inspections of globe
(Daylite) changing process. splinters to the lights are done
eyes. every Tuesdays
EFP007 Normal working Dark stairwells should Injury or fatality X N 3 50 Regular lighting inspections by None GSR85
OHS Sec
0f 6,13
1993 Sec 8 2 4 0 8 48 54
ONPHS conditions in new & old the lights be out and not due to tripping stairwells .Daily residential contractor. 20 Lux
hall yet fixed. down stairwell. exposure required down stairs. Emergency
lighting. Alternative routes &
Backup Power
CR Sec
GSR Sec7,8,14,15
3
EFP008 Walking too close to hot Some of the heated People burning X N 2m unlagged 120 PPE, warning signs on pipes, None OHS 85 0f 1993 Sec 8 2 5 0 10 70 70 (T)
ONPHS surfaces/pipes or pipes not being lacgged themselves due to pipe at + 60 induction
machinery in the or clearly identified. contact with hot degrees.Daily
Margarine Hall. surfaces - exposure
supperficial burn
wounds such as Hygene & ergonomic
blisters. Surveys
EFP009 Process plant Operates with air Damage to plant X N 10 MPU’s N/a Engineering daily inspections, well None OHS 85 0f 1993 Sec 8 2 5 0 10 70 70 (T)
ONPHS causing process equipment also experienced operators
vibration and possibility of injury.
subsequent property
damage
Hygene & ergonomic
EFP010 Normal use, wear and Unmonitored corrosion Ammonia X N 32 barrels.Daily 10 13 week inspections by None OHS 85 0f 1993 Sec 8 &
Surveys 5 4 0 8 72 64
ONPHS tear / Deterioration of the could cause ammonia inhalation, exposure engineering. RCM 14
Ammonia barrels inside leak or ruptured pipes. Asphyxiation, injury
the Schroeder or fatality.
3 Ammonia Ammonia leaks Ammonia Use Original spare parts GSR Sec 2,5,7
Incidents inhalation, (especially the O Rings)
Asphyxiation, injury
or fatality.
X E 32 barrels.Daily 20 HCSR SEC1-17

EFP011 Normal use, wear and Unmonitored corrosion Ammonia 13 week inspections by engineers. None OHS 85 0f 1993 Sec 8 & 5 4 0 8 72 64
ONPHS tear / Deterioration of the could cause rupture of inhalation, exposure Available on 14
Ammonia barrels inside vessels Asphyxiation, injury RCM on SAP.
the Schroeder or fatality. Emergency Procedure
12.6
MHIR
GSR SecSec 1-10
2,5,7
EFP012 Normal use, wear and Deterioration of Ammonia X N 64 seals.Daily 20 Replace seals when small leak None OHS 85 0f 1993 Sec 8 & 3 4 0 10 70 70 (T)
ONPHS tear / Deterioration of the ammonia seals leading inhalation, exposure detected (smell) 14
Ammonia barrels inside to large leak Asphyxiation, injury
the Schroeder or fatality. Refer to CAPEX 2009
HCSR SEC1-17
GSR Sec 2,5,7
Page 2 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP013 Supply of Liquid Liquid becomes trapped Ammonia X E 32 Ammonia 20 Procedure for draining of None OHS 85 0f 1993 Sec 8 & 3 1 0 8 32 50
ONPHS Ammonia to the Barrels in ammonia system, inhalation, units ammonia. Emergency 14
inside the MPU from the builds up pressure and Asphyxiation, injury Procedure 12.6
Fridge Plant causes rupture or fatality.
GSR Sec 2,5,7
EFP014 Normal plant utilisation Inadequate replacement Burning of people X N 60 m of piping 1 Replace corroded steam piping None OHS 85 0f 1993 Sec 8 & 4 3 0 9 63 63 (T)
ONPHS of Steam lines behind P of corroded pipes could around the pipe when reported. RCM & 14
tanks lead to rupture that has ruptured, Inspections
people burning HCSR SEC1-17
themselves due to
contact with hot GSR Sec 2,5,7
surfaces -
supperficial burn
wounds such as MHIR Sec 1-10
blisters.
HCSR SEC1-17
EFP015 Opening valves on Incorrect operation of Property damage X N 3 2 Experienced artisans. SOP's for None OHS 85 0f 1993 Sec 8 & 3 9 0 4 48 36
ONPHS steam lines behind P opening steam valves - and serious injury. valves.Opened opening High-Pressure Steam to 14
tanks exposure to steam. If steam blows during prevent Water Hammer Effect.
directly into eyes maintenance/sh MHIR Sec 1-10
blindness may utdown
occur. /breakdown GSR Sec 2,5,7
EFP016 Pushing the rework Trolley with broken Employee can fall X N 25 trolleys are 40 Awareness has been done with None OHS 85 0f 1993 Sec 8 3 2 0 8 40 64
ONPHS trolleys in the Packing wheels/ missing tiles on and get injured or pushed daily employees that they must not use
Hall the floor break a bone. trolleys with broken HCSR SEC1-17
wheels.Hazard spotting exercise
in place
Hygene & ergonomic
Surveys
MHIR Sec 1-10
EFP017 Loading Boxes down the Boxes coming down Boxes coming X N 10 chutes / 10 40 Chutes are desiged with lips so None OHS 85 0f 1993 Sec 8 3 5 0 8 64 64 (T)
ONPHS chutes for packing chute travel at a speed. down chute may loads per shift that no person has to catch boxes
injure persons as they come down. Employees
hand at bottom of are not allowed to put their hands
chutte if his /her inside the chute during loading
hand is left inside Hygene & ergonomic
the chute during Surveys
loading of boxes
EFP018 Loading Boxes down the Continual wear of chutes Possible structure X N 10 chutes / 10 4 TPM AM Tagging system used to None OHS 85 0f 1993 Sec 8 4 2 0 9 54 60
ONPHS chutes for packing could cause metal collapse and/or loads per shift identify sharp edges
fatigue. injury to people.
Hygene & ergonomic

Surveys
Page 3 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP019 Loading Boxes down the Overloading of chute Person falling into X N 10 chutes / 10 4 One point lesson completed None OHS 85 0f 1993 Sec 8 2 2 0 9 36 50
ONPHS chutes for packing causing may cause chute or load of loads per
blockages boxes Whilst trying shift.Daily
to unblock the exposure
blocked boxes in
the chute, serious Hygene & ergonomic
injuries Surveys
EFP020 Changing of nozzles on Incorrect changing of Serious injury to X N 3 changes per 4 Only trained operators change None OHS 85 0f 1993 Sec 8 & 4 8 0 6 72 72
ONPHS B -Unit line 1 nozzles on line 1 person. week It normally nozzles 14
takes 5-10
minutes to
change a nozzle
GSR Sec 2
EFP021 Use of /picking up Incorrect use of carolina Injury / property X N 2 workshop 2 Register of inspections, lifting None OHS 85 0f 1993 Sec 8 & 5 4 0 5 45 54
ONPHS equipment with carolina (mobile crane) damage and legal crane.Its only equipment training. All workers 14
complications. used when trained and workers are using the
there is a need carolina under supervision
DMR Sec 18
EFP022 Climbing into Tanks for Hot oil / liquid lands on Severe burns on X A 24 tanks /and 1 Work permits, lockout, and vessel None OHS 85 0f 1993 Sec 8 & 7 2 0 2 18 30
ONPHS Maintenance person whilst inside the the face and body are entered Bi- entry procedure, 14
tank which may result in annually or
death. when there is a
need
GSR Sec 5&7
EFP023 Welding inside tanks Gas fills spaces causing Asphyxiation, injury X A 24 tanks and 1 Lockout, work permits, gas None OHS 85 0f 1993 Sec 8 & 8 7 0 1 15 15
ONPHS in the Tank or fatality. welding is only monitoring, extraction fans 14
done inside the
tank when
there is a need
GSR Sec 5&7
EFP024 Welding inside tanks Tank could be slippery Injury by falling. X A 24 tanks and its 1 Tanks washed and drained before None OHS 85 0f 1993 Sec 8 & 6 6 0 1 12 12
ONPHS and may be difficulty for very rare to do use 14
employee to get out welding inside
tanks
GSR Sec 5&7

EFP025 Adjusting case packer Being hit by machine / Severe injury to X N 7 case packers 1 Trained artisans and are familiar None OHS 85 0f 1993 Sec 8 & 4 1 0 5 25 36
ONPHS machine whilst running bumped to it whilst hand or fingers, and are with case conditions / designs 14
underneath it doing even the loss of a adjusted when
adjustments limb. there is a need
GMS Sec 1,2,3,4,5,6,7
Page 4 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP026 Normal processing of Spillage of margarine in Slip and fall, Injury, X N 12.7m2 affected 40 PPE, 5S housekeeping audits in None OHS 85 0f 1993 Sec 8 & 2 5 0 9 63 63 (T)
ONPHS margarine the plant could lead to fatality or even at a time.Daily Old and New Packing Hall on 14
slippery conditions paralysis. exposure weekly basis and keeping proof
thereof. TPM AM cleaning
daily.Drip trays provided
ERW Sec 6
EFP027 Work on gearboxes / Spillages on floors of oils Slip and fall, Injury, X N 2.5 litres of oil 5 PPE, good housekeeping.Drip None OHS 85 0f 1993 Sec 8 & 4 5 0 5 45 60
ONPHS machinery can lead to slippery fatality or even per gearbox and trays used when draining oil from 14
conditions paralysis. and this is only the gearbox
done during
breakdowns or
shutdown ERW Sec 6
EFP028 Normal processing of Caustic pipe leak Leak could drip on X N Concentration na/ Regular maintenance, Safety None OHS 85 0f 1993 Sec 8 & 2 5 0 6 42 54
ONPHS margarine to aluminium shoe 1% of caustic Showers.MSDS C.12 14
of BDR causing
reaction creating
hydrogen gas, fire
or exposure to GSR Sec 2,5,7
people. Injury to
people
EFP029 Adding solvent to Date Accidental or work- Poisining from X N 500ml per 5 Design of bottle, sealed with foil None OHS HCSR
85 0f 1993 Sec 8 &
SEC1-17 3 5 0 6 48 63
ONPHS Coder machine related contact or product or serious application cap which is only broken once on 14
inhalation of chemical health problems, machine, training to ensure that
substances from normal Slip and fall, Injury, the solvent is locked in a
use or spillage fatality or even cupboard. Surgical Gloves used
paralysis. whilst handling due to short-term GSR Sec 2,5,7
usage.Linx Marque Solvent
1512, MSDS no. L.13.
HCSR SEC1-17
EFP030 Storage of Oils inside the If tanks overflows due to Injury, fatality or X N 400 tons in a 120 Spill kit available and employees None OHS 85 0f 1993 Sec 8 & 3 3 0 8 48 56
ONPHS DO Tanks faulty equipment oil can even paralysis. tank and 8 DO trained in spill control. 14
spill to the floor and tanks Regular
cause slippery maintenance of level transmitter.
conditions which may Overflow line
lead to injuries to provided. SOP ERW Sec 6
passerbys if they are not 7.5.14.3
carefull when walking
GSR Sec 3
EFP032 Working on ammonia Uncontrolled release of Fire or explosion. X E R250 20 Work permit procedure, safe None OHS 85 0f 1993 Sec 8 & 7 2 0 1 9 9
ONPHS lines ammonia whilst cutting Injury or fatality 000.Activity is ammonia working 14
and welding pipelines (Asphyxiation) done when procedures.Ammonia
could cause ignition there is a need / Anhydrous, MSDS no. A06.
source causing breakdown Emergency Procedure 12.6
explosion. GSR Sec 2,5,7
HCSR SEC1-17
Page 5 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP033 Storing of Chemicals Inadequate/ improper Fire or explosion. X N ± 1185 5 Flavour store locked key held by Fire can OHS 85 0f 1993 Sec 8 & 5 2 0 10 70 70 (T)
ONPHS storage of chemicals Injury or fatality kg.Crearasa,BK responsible persons, controlled spread to 14
(Asphyxiation) V 45 & 85,Lis temperature. Alarm in place.Fire adjacent
24,Sen03, extinguishers available,sprinkler buildings
ES144 system and emergency team
available GSR Sec 2
EFP034 Chemical storage If aircon in flammable Fire or explosion. X N ± 1185 / R500 8 Alarm in place giving indication of None OHS 85 0f 1993 Sec 8 & 4 2 0 10 60 60 (T)
ONPHS store fails, fire could Injury or fatality. 000.Crearasa,B temperature increase. Fire 14
break out KV 45 & 85,Lis Warning system being HCSR SEC1-17
24,Sen03, implemented, . Trained Fire-
ES144 Fighters on shift, extinguishers
available. GSR Sec 2
Dangerous Goods
EFP035 Case Packing machine Improper stacking on Injury, fatality or X N 25 boxes in 28 Good stacking practices, None storage
OHS 85 Permit
0f 1993 Sec 8 & 2 2 0 9 36 36
ONPHS case packing machine even paralysis. bundle / 10 housekeeping 14
could lead to boxes bundles. HCSR SEC1-17
falling over or causing All
tripping hazard. casepackers.
Daily exposure GSR Sec 8
EFP036 Working on moving Overall (non – Serious injury or X N Artisans work 5 Lock out procedure, trained None Dangerous
OHS Goods
85 0f 1993 Sec 8 & 5 3 0 8 64 64 (T)
ONPHS machinery by artisan elasticated sleeves) loss of limb. on machine personnel. No work done on storage Permit
14
could get caught in during moving equipment, except
moving machinery. breakdowns or FAULT-FINDING. Unless declared
during fault competant.
finding.Daily GMR Sec 1,2,3,4,5,6,10
exposure
EFP037 Working on moving Abusing PPE by cutting Cuts , burns and X N Daily exposed 5 PPE standards in place None OHS 85 0f 1993 Sec 8 & 2 4 0 7 42 42
ONPHS machinery by artisan overall sleeves which exposure to to 80 degrees 14
exposes the workers chemicals.
arms.
EFP038 Working on moving Lack of awareness by Serious injury or X N 2 main 15 Induction, warning None OHS 85 Sec
GMR 0f 1993 Sec 8 &
1,2,3,4,5,6,10 4 2 0 8 48 48
ONPHS machinery new people in dept (i.e loss of limb. conveyors / 12 signs.Equipment risk assessment 14
why alarm is going packing lines induction done to all new
on/off for conveyors employees.
starting up). Putting
hands in conveyors GMR
GSR Sec
Sec 1,2,3,4,5,6,10
2
unaware that it can start
at anytime.
EFP039 Working on moving Not perfoming lock out Serious injury or X N As per 20 Supervision, All maintenance None OHS 85 0f 1993 Sec 8 & 6 6 0 6 72 72 (T)
ONPHS machinery loss of limb. maintenance or people issued with correct lock out 14
project equipment(caliper, lock, valve and
work.Daily chain) on lockout, register
exposure to all available for all padlock owners
lines GMR Sec 1,2,3,4,5,6,10
Page 6 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP040 Working on moving If machinery runs Serious injury or X N Daily exposed 10 Daily walkabout supervision, Lost None OHS 85 0f 1993 Sec 8 & 5 2 0 10 70 70 (T)
ONPHS machinery without machine guards loss of limb. to 15 lines time record can identify who 14
or guards not replaced worked on line, Awareness done
after maintenance this to operators.
will lead in machinery
running with moving GMR Sec 1,2,3,4,5,6,10
parts exposed and if
people put their hands in
that exposed machines
they can get serious
injuries
EFP041 Maintenance on Goods Procedures not being Injury, fatality or X N 2 lifts / 2.5 tons 2 Appointment of competent None OHS 85 0f 1993 Sec 8 & 8 4 0 5 60 60 (T)
ONPHS lift / elevator adhered to by competent even paralysis. each contractors 14
3rd party or using lift
incorrectly.
GMR Sec 1,2,3,4,5,6,10

EFP042 Normal operation of Filling up of lift shaft with Possible X N 5m3 water.Daily N/a Sump pump available in the lift to None OHS 85 0f 1993 Sec 8 & 2 4 0 10 60 60 (T)
ONPHS lift/elevator water from floor electricution or exposure .2 lifts pump out water from the shaft.Lift 14
washings / spillages fatality. serviced regularly according to the
causing shorting out of contract
electrics and this will
lead to lift breaking GMR Sec 1,2,3,4,5,6,10
down/jammed
EFP043 Pregnant woman walking Exposure to extreme Heat stroke could X N Not easy to 1 Medical induction done. None OHS 85 0f 1993 Sec 8 7 10 0 3 51 51
ONPHS through EF&P factory heat conditions lead to miss quantify
carage.
Hygene & ergonomic

EFP044 Operation of Ammonia Insufficient venting pipe Injury, fatality and X E 32 barrels / R26 10 Daily inspection by Aldo None Surveys
OHS 85 0f 1993 Sec 8 & 4 2 0 10 60 60 (T)
ONPHS pipes in old hall for ammonia leading to exposure to 000 each Emergency Procedure 14
inadequate pressure ammonia 12.6
relief leading to (asphyxiation)
catastrophic failure of ERW Sec 2
the barrel GSR Sec 2,5,7
EFP045 Pushing live steam line Solidified fats blocking Severe 3rd degree X N 3 bar steam and 1 Ensure drain steam tracing None OHMS 85 0f 1993 Sec 8 & 5 2 0 4 28 40
ONPHS down drain to unblock the drain burns and this is only done functional and fully effective line 1 14
solidified fats complications due when drains - (cause of blockage filter / drain
to infection. are blocked
HCSR SEC1-17
CR Sec 7
EFP046 Processing with Cold Hot water used to heat Water could burn X N 80 degree water 10 Awareness None OHS 85 0f 1993 Sec 8 & 5 3 0 8 64 64 (T)
ONPHS pipes on the lines up pipes passers by / daily esposure 14 MHIR Sec 1-10
operator, Burn especially in GSR Sec 2
wounds and winter
blistering.
CR Sec 7
GSR Sec 2
Page 7 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP047 Processing with Cold Insufficient heating of Possible injury to X N 10 heat n/a Maintenance in place None OHS 85 0f 1993 Sec 8 & 4 2 0 5 30 30
ONPHS pipes on the lines safety valves to allow staff nearby. exchangers / 14
clearing of safety valves R40 000 per
resulting in it not heat exchanger
operating correctly to repair
leading to property GMR Sec 1,2,3,4,5,6,7
damage
EFP048 Use of Powertools and If water on floor Possible X N 220 volts>Daily 2 Registers, Inspections, and the None OHS 85 0f 1993 Sec 8 & 7 2 0 8 72 72 (T)
ONPHS extension cables electricution can take electricution or exposure policy of unilever is not to have 14
place if cord has fatality. extensions with joints.
exposed wires and
employee touches it
GMR Sec 1,2,3,4,5,6,7
EFP049 Operation of Date Suspect plugs for date Possible X N 15 date coders 10 Engineering site standard. Hazard None OHS 85 0f 1993 Sec 8 & 7 2 0 8 72 72 (T)
ONPHS Coders coders not IP65, could electricution or daily exposure spotting exercise 14
lead to electric shock fatality.
when came into contact
with EMR Sec 2,9,13
GSR Sec 2
EFP050 Working with sharpened Tool slips and person Open wound that X N Daily exposed 20 Hand tool checks done. None OHS 85 0f 1993 Sec 8 & 3 3 0 8 48 64
ONPHS tools cuts themselves would require to various 14
stitches or possible handtools
loss of an eye.
GSR Sec 2
EFP051 Performing of general Unsafe use of Possible X N Daily exposed 5 Area barricaded, PPE, work None OHS 85 0f 1993 Sec 8 & 3 2 0 6 30 36
ONPHS maintenance in area powertools could lead to electricution or to 220volt permit 14
possible injury to fatality. power tools
surrounding persons /
operator
EFP052 Performing of general Use of incorrect tools for Open wound that X N Daily exposed 5 Supervision of contractors None OHS 85Sec
GSR 0f 1993
2 Sec 8 & 1 3 0 6 24 36
ONPHS maintenance in area job could lead to injury would require to various 14
stitches or possible handtools
loss of an eye.
EFP053 Performing of general Getting fingers caught in Serious injury or X N Daily exposed 20 Supervision, training, safety talks, None GSR
OHS 85Sec 2 Sec 8 &
0f 1993 3 3 0 6 36 42
ONPHS maintenance in area machinery whilst loss of limb. to 15 lines Induction format modified to 14
carrying out incorporate awareness
maintenance
EFP054 Performing of general Incorrect lock out Electrocution, X N Daily exposed 2 Supervision, All maintenance None OHS 85Sec
GSR 0f 1993
2 Sec 8 & 5 3 0 8 64 64 (T)
ONPHS maintenance in area procedure may lead to fatality, injury or to 15 lines people issued with correct lock out 14
equipment being started loss of limb equipment(caliper, lock, valve and
up and injuring persons chain) on lockout, register
available
GSR Sec 2
EFP055 Climbing stairs carrying Operators could slip Injury, fatality or X N 11 kg – 25 kg 8 Modified step treads for maximum Person OHS 85 0f 1993 Sec 8 & 4 4 0 8 64 72
ONPHS buckets of hot liquid whilst on stairs injuring even paralysis. daily exposure grip burns from 14
themselves hot liquid in
bucket if he
slips
Page 8 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP056 Climbing stairs carrying Person burns from hot Serious burn X N 11 kg – 25 kg / 8 PPE worn by operator None OHS 85 0f 1993 Sec 8 2 8 0 7 70 80
ONPHS buckets of hot liquid liquid in bucket if he slips wounds and 75 degrees
complications due
to infection.
EFP057 Pressure testing of Catastrophic failure of Possible injury to X E 22 bar / 10 Engineering design, pressure None Hygene
OHS 85 &
0fergonomic
1993 Sec 8 4 5 0 1 9 9
ONPHS ammonia barrels the vessels with injury to staff nearby. water.Done 3 vessel regulation adherence Surveys
personnel in the area yearly Emergency Procedure 12.6
Basic Conditions of
EFP058 Hoseplay at the People can get hurt / Injury or fatality. X N Daily exposure 50 Supervision.Induction.SHE talks None Emplyment.
OHS 85 0f 1993 Sec 8 & 3 1 0 8 32 48
ONPHS workplace propery damage if they 14
are playing /teasing
each other at the
workplace
EFP059 Personnel / temporary Lack of induction / and Injury or fatality. X N Daily exposed 10 Induction, work permit, audits None OHS 85 0f 1993 Sec 8 & 4 1 0 8 40 56
ONPHS workers working in area safe work permits can to 10 permanent 14
cause injury to persons if contractors
they interfere or used
equipment that they are
not trained or wander in GSR Sec 2
areas where they are not
supposed to be
EFP060 Visitors entering area Unaccompanied visitor Injury or fatality. X N weekly exposed 1 Supervision in area, accompanied None OHS 85 0f 1993 Sec 8 & 4 2 0 8 48 56
ONPHS under normal working could wander into area to +/-5 people visitors, signage 14CR Sec 7(9)
conditions and get injured due to
lack of knowledge of the
area
EFP061 Repairing stirrer on DO Stirrer can slip and fall Injuries to x N 2 times a year 1 Done by artisan and they also use The shaft OHSGSR
85 Sec 2 Sec 8 &
0f 1993 4 5 0 3 27 27
ONPHS tank whist being taken out by employees who are especially lifting equipement and scaffolding can also get 14
employees. taking it out and during damaged
below the tank. shutdown and
also when there
is a need to CR SecSec
GSR 7(9)2
repair
EFP062 Taking samples under Employees can get Burn wounds and X N Samples are 1 Operators trained in proper way of Sample OHS 85 0f 1993 Sec 8 & 2 3 0 5 25 25
ONPHS DO tanks burnt by oil if they blistering. taken during taking samples bottle can 14CR Sec 7(9)
overfill the sample bottle batch fall to the
changeover and ground and
also once the oil cause
has been stored spillage GSR Sec 2
at the tank for a
long time.Oil
tempreture 650
CR Sec 7(9)
Page 9 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP063 Changing swing bends Opening the swing Burn wounds and X N Only opened 1 Operators trained.Spanner None OHS 85 0f 1993 Sec 8 & 4 5 0 7 63 63 (T)
ONPHS bends without closing blistering. during CIP's.All provided 14
valves may lead to the lines.Water 550
release of hot water
GSR Sec 2,5,7
EFP064 Changing swing bends Opening the swing Chemical burn X N Only opened 1 Operators trained.Spanner None OHS 85 0f 1993 Sec 8 & 5 5 0 7 70 70 (T)
ONPHS bends without closing wounds and during CIP's.All provided 14
valves blistering. lines.Caustic
temperature 750 HCSR SEC1-17
GSR Sec 2,5,7

EFP065 Working on propotional The propotional pump Injury to foot or leg. X N Only worked on 2 Done by 2 people with the help of Property/ OHS 85 0f 1993 Sec 8 & 5 5 0 3 30 30
ONPHS pump head is heavy and if falls it during lifting equipment Equipment 14
whillst working on it or maintenance damage if it
removing it and breakdown falls
HCSR SEC1-17
GSR Sec 2
EFP066 Clearing blockages in If a leak occur during Burn wounds and X N Only done when 2 Done by APV.Permit to Work is None OHS 85 0f 1993 Sec 8 & 2 3 0 3 15 15
ONPHS the Heat Exchanger pressure testing hot blistering. there is a need issued to them. 14
water can spray & burn
employees around that CR Sec 7(9)
area.
GSR Sec 2
EFP067 Doing maintenance on If plates are not properly Injury to foot or leg. X N Only done when 8 Done by APV None OHS 85 0f 1993 Sec 8 & 2 3 0 3 15 15
ONPHS the heat exchanger stacked they can fall and there is a need 14
cause injuries DMR Sec 18
EFP068 Changing cup seals in If the pump is not Injury or loss of X N Only done when 8 Done by an artisan and pump is None CR 85
OHS Sec0f7(9)
1993 Sec 8 & 5 4 0 7 63 48
ONPHS LP and Proportion pump properly isolated it can limb. there is a need isolated and locked 14 GSR Sec 2
start automatical and
cause injuries whilst the
artisan is busy changing
cup seals GSR Sec 2
CR Sec 7(9)
EFP069 Taking out Unit A1 rotor Rotor is heavy and if it Injuries to X N 200kg.Its taken 5 Only taken out during Rotor can OHS 85 0f 1993 Sec 8 & 7 8 0 4 60 60 (T)
ONPHS for repairs / maintenance is not held properly it can personnel if scrapper maintenance or repairs usinng get 14
slip and fall. removing it - Hand blades are worn lifting equipment damaged if it
feet & leg. out and also slips and CR Sec 7(9)
during planned falls whilst
maintenance being GSR Sec 2
and also during removed
breakdowns.In
all schroeders DMR Sec 18
CR Sec 7(9)
EFP070 Taking out Unit C1 shaft Shaft is heavy and if it is Injuries to X N 40-50kg and its 2 Done by trained artisans and Shaft can OHS 85 0f 1993 Sec 8 & 5 6 0 3 33 55
ONPHS for repairs / maintenace not held properly it can personnel taken out for also uses lifting equipment when get 14
slip and fall and cause removing it - Hand maintenance or taking it out damaged if it
injuries to personnel feet & leg. during falls
removing it breakdown DMR Sec 18
GSR Sec 2
Page 10 of 75 CR Sec 7(9)

Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP071 Taking out A2 rotor Rotor is heavy and if it Injuries to X N 200kg.Its taken 5 Activity is done by an Artisan and None OHS 85 0f 1993 Sec 8 & 7 8 0 3 45 60
ONPHS shaft for repairs / is not held properly it can personnel if scrapper is taken out by two people during 14
maintenance slip and fall and cause removing it - Hand blades are worn maintenance or repairs usinng
injuries to personnel feet & leg. out and also Caroline lifting equipment
removing it during planned
maintenance GSR Sec 2
and also during
breakdowns.In
all schroeders
and unitators
CR Sec 7(9)
EFP072 Working on diverter The diverter get Employees can get X N Line 7 & 8.Daily 2 Operator trained n/a OHS 85 0f 1993 Sec 8 & 3 5 0 8 64 64 (T)
ONPHS activated whilst they are hand injuries. exposure 14
busy clearing the DMR Sec 18
blockage.
GSR Sec 2,5,7

EFP073 Changing swing bends If velve is not closed Burn wounds and X N CIP is done 4 Operator trained None OHS 85 0f 1993 Sec 8 & 4 4 0 8 64 64 (T)
ONPHS before opening the blistering. during change 14
operator can get burnt Chemical burns. over and when
by CIP there is a need.
HCSR SEC1-17
GSR Sec 2
EFP074 Feeding reel on the BDR Employee can get Loss of finger or X N Changed hourly 24 SOP .Only trained operators None OHS 85 0f 1993 Sec 8 & 3 5 0 9 72 72 (T)
ONPHS machine injured if he accidentaly limb. in Line 7 & 8.In changed the reels 14
put his hand under 500g changed
cutting knives every 45
minutes. CR Sec 7(9)
CR Sec 7(9)
GSR Sec 2
EFP075 Clearing paper jam on If two people are doing Serious injuries or X N Daily exposure 16 Only one person must perform n/a OHS 85 0f 1993 Sec 8 & 5 5 0 9 90 90 (T)
ONPHS the BDR machine this task chances are possible to all BDR this task.Operators trained 14
high that there can be amputation. machines and
miscommunication this activity is DMR Sec 18
between the one turning only done when CR Sec 7(9)
the wheel and the one there is a GSR Sec 2
clearing the jammed paperjam
paper and the one
clearing the paper can
be cut by knives. DMR Sec 18
EFP076 Changing cutting knives Artisans can get cut by Laseration to X N In all brick lines 4 Done by artisans only.Extra OHS 85 0f 1993 Sec 8 & 3 5 0 4 32 32
CR Sec 7(9)
ONPHS in the BDR machine cutting knives when fingers or hand. and its changed caution needed when changing 14
changing knives (Stitches required) quartely or also knives
when there is a
need
GSR Sec 2
GMR Sec 2,3,4,5,7
CR Sec 7(9)
GMR Sec 2,3,4,5,7
Page 11 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP077 Adjusting / positioning If somebody turns the Serious injuries or X N Done during 4 Done by artisans.Lockout is done n/a OHS 85 0f 1993 Sec 8 & 4 5 0 7 63 63 (T)
ONPHS Breakrollers handwheel whilst possible maintenance.Ro 14
another employee is amputation. ller weighs 5kg
doing adjustments and there are in
without warning him ,the Line
one doing adjustments 5,7,8,14,15.Also GSR Sec 2
can get injured if the paper is
rolling
backwards or if
its skewed
CR Sec 7(9)
EFP078 Removing unwrapped Employee can get Serious injuries or X N Daily exposure 8 Its only done by an operator alone None OHS 85 0f 1993 Sec 8 & 5 3 0 9 72 72 (T)
ONPHS bricks from the moulding injured if someone turns possible in all bricks 14
drum the wheel whilst busy amputation. machines.This
removing unwrapped is done if GMR Sec 2,3,4,5,7
brick wrapper is
jammed in GSR Sec 2
wrapping table
and also if the
electric sensor
CR Sec 7(9)
EFP079 Adjusting the moulding The chain on the chain Injury to hands, X N Its only done 2 Lockout procedure is followed Equipment OHS 85 0f 1993 Sec 8 & 4 3 0 3 21 24
ONPHS drum shoe block can snap and it foot or leg. when there is a and the shoe must be damage 14
can accidentally drop the serious leak and empty.Chain is checked quartely
unit. also during and loadtested annually by a 3rd
replacing.6 party GMR Sec 2,3,4,5,7
monthly .2 GSR Sec 2
tons.In all
BDR's in the
department
CR Sec 7(9)
EFP080 Adjusting the jaw unit Artisan can get injured Serious injuries or X N Its only 2 Done by artisans.Machine is n/a OHS 85 0f 1993 Sec 8 & 5 4 0 8 72 72
ONPHS whilst doing adjustments possible adjusted when stopped.Main BDR door is opened 14
if another employees amputation. there is poor during adjustments to avoid any
turns the handwheel wrapping. unnecessary start ups.Lock out
Daily exposure procedure GMR Sec 2,3,4,5,7
GSR Sec 2
EFP081 Taking product samples Employee can get Laseration to X N Samples are 20 Sharp edges are filled out when Product OHS 85 0f 1993 Sec 8 & 2 4 0 8 48 54
ONPHS from a running line injured by unknown fingers or hand. taken 2 times discovered.Hazard spotting done contaminatio 14CR Sec 7(9)
sharp edges on the (Stitches required) per shift in a line n
conveyor whilst taking and also during
samples batch change
and this applies GSR Sec 2
to all lines GMR Sec 2,3,4,5,7
except bulk line
EFP082 Changing / Replacing If pulling a tape to put it Laseration to X N Tape sealer in 7 Trained operators None OHS
CR 85
Sec0f7(9)
1993 Sec 8 & 5 5 0 8 80 80 (T)
ONPHS tape sealer into the buffer rollers the fingers or hand. all 7 lines, two 14
blade can cut and injure (Stitches required) times per shift
the employee for 3 mins
Page 12 of 75 GSRSec
GMR Sec2,3,4,5,7
2
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP083 Replacing seal on the If someone start using Serious injuries or X N Done during 4 Done by Artisans, lock out None OHS 85 0f 1993 Sec 8 & 5 5 0 3 30 40
ONPHS dosing valve (Line 6) the pump without a possible break down and procedure 14
proper lock out, he can amputation. during
get injured maintanance
EFP084 Working on the dosing Shaft is heavy and can Injuries to X N During 2 Done by Artisans, lock out Burns from OHS GSR
85 Sec 2 Sec 8 &
0f 1993 6 4 0 3 30 40
ONPHS shaft ( Line 6) fall when pulling and personnel maintanance procedure touching hot 14
has hot surfaces removing it - Hand and breakdown surfaces
feet & leg.
CR SecSec
GSR 7(9)2
EFP085 Replacing V belt on When isolation is not Serious injuries or X N During 4 Done by Artisans, lock out None OHS 85 0f 1993 Sec 8 & 5 5 0 6 60 60 (T)
ONPHS Unitator properly done whilst possible maintanance procedure in place 14
replacing V belts done amputation. and breakdown
and one starts using the
machine, the hands can GMR Sec7(9)
CR Sec 2,3,4,5,7
get injured GSR Sec 2
EFP086 Working on a scrapper Sharp scrapper blades Laseration to X N During 4 Done by Artisans, None OHS 85 0f 1993 Sec 8 & 5 6 0 6 66 66 (T)
ONPHS blade - Unitator can injure an employee's fingers or hand. maintanance 14
hand if (Stitches required) and breakdown
GMR Sec 2,3,4,5,7
CR Sec 7(9)
GSR Sec 2
EFP087 Working on a schroeder Employees can get Injuries to X N Gearbox weighs 6 Done by an artisans with None OHS 85 0f 1993 Sec 8 & 6 4 0 4 40 50
ONPHS gearbox injured when taking out personnel 100kg. somebody helping 14
gearbox if he/she lost removing it - Hand Done when
grip due to oily surface feet & leg. there is a GMR Sec 2,3,4,5,7
breakdown or CR Sec 7(9)
during GSR Sec 2
maintenance
EFP088 Cleaning spillage in the If an employee entered a Injuries to X N Continous 4 8 Only enter through spur door Serious OHS 85 0f 1993 Sec 8 & 5 5 0 6 60 60 (T)
ONPHS robot spur in order to clear personnel roborts 9 injury 14
GMR Sec 2,3,4,5,7
spillage or through pallet removing it - Hand spurs.Only
CR Sec 7(9)
exit the robot can feet & leg. entered when
automatically start there is a need
GSR Sec 2
EFP089 Closing robot grippers If the robort Serious injury or X N Done when 8 Done by Trained supervisor None OHS 85 0f 1993 Sec 8 & 7 5 0 5 60 72
ONPHS manually mechanically brake or fatality. there is a need 14
GMR Sec 2,3,4,5,7
fails, and air loss happen or a breakdown.
while still working, it can Brake
fall on a persons head. weighs 2 tons CR Sec 7(9)
GSR Sec 2
EFP090 Robort maintanance If lock out is not done Serious injuries or X N Done when 8 Done by an artisan and following None OHS 85 0f 1993 Sec 8 & 6 7 0 5 65 65 (T)
ONPHS correctly, it can start possible there is a need a lock out procedure GMR Sec 2,3,4,5,7
14
automatically amputation. or a breakdown. CR Sec 7(9)
EFP091 Cleaning track shuttle Shuttle car can bump on Injuries to X N 15 min daily 4 Isolate and lock machine None OHS 85 0f 1993 Sec 8 & 5 5 0 6 60 60 (T)
ONPHS car employee if on the way personnel during shift start 14 GSR Sec 2
removing it - Hand up
feet & leg. GMR Sec 2,3,4,5,7
EFP092 Cleaning of rollers under Employee can be Burn wounds and X N When there is a 5 Operator trained None OHSGSR
85 Sec 2 Sec 8 &
0f 1993 6 5 0 6 66 66 (T)
ONPHS the glue pot burned by glue if sensor complication need 14CR Sec 7(9)
is not working through infection.
Page 13 of 75
CR SecSec
GSR 7(9)2
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP093 Walking through the Employees/contractors Injury or fatality. X N Daily exposure 40 Demacated areas , signages None OHS 85 0f 1993 Sec 8 & 7 3 0 8 80 80 (T)
ONPHS palletising area can be injured by the mainly during displayed at the entrance, 14
folklift moving within the the day Induction, safety talks
area
EFP094 Operating packing If operators overide Serious injury or X N Daily exposure 50 Operators trained.Awareness n/a OHSGSR
85 Sec 2 Sec 8 &
0f 1993 5 4 0 8 72 72 (T)
ONPHS machines in EF&P and safety switch/devises fatality. to all machines done 14
Bottling he/she can put
employees lifes in
danger if anything goes
wrong in the machine CR SecSec
GSR 7(9)2
EFP095 Cleaning swelling on the If any employee clean Serious injuries or X N Daily exposure 8 Equipment induction done and Production OHS 85 0f 1993 Sec 8 & 4 5 0 8 72 72 (T)
ONPHS tub filling whilst machine the swelling using a loss of limb. in all tub lines operators trained.SOP 7.5.5.2 loss 14
GMR Sec7(9)
CR Sec 2,3,4,5,7
is running mutton cloth whilst the
machine is running the
cloth or the hand can be Operators have been trained.
get caught in the GSR Sec 2
machine. GMR Sec 2,3,4,5,7
EFP096 Removing untapped box Employee can be hit by Injury to hand & X N Daily exposure 40 Operators trained .SOP 7.5.5.3 Can possible OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 80 (T)
ONPHS from tape sealer a monkey tail whilst fingers. in most lines be cut by 14CR Sec 7(9)
removing box from the blades whilst
tape sealer if isolation removing
is not done untapped
boxes in the GSR Sec 2
sealer GMR Sec 2,3,4,5,7
CR Sec 7(9)
EFP097 Unjamming tubs nesting If employees are Serious injury. X N Daily exposure 26 Ladders provided and operators n/a OHS 85 0f 1993 Sec 8 6 4 0 8 80 80 (T)
ONPHS in the A frames standing on the top in tub lines trained.
machine whilst doing
work on A frames
chances are high that Ladder has been added on Line GMR Sec 2,3,4,5,7
they can slip from the 12 GSR Sec 6,13
machine and get injured
especially on the hip
EFP098 Aircraft movement Passanger plane Fatalities/ injuries X A 20 000 Litres of 250 Emergency Procedure - 12.6 None Aviation Act, 1962 (Act No. 10 5 0 6 90 96
ONPHS accident/ crash on site Jet Fuel CRof
74 Sec 8
1962)
Page 14 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP099 Swarming bees settling Attack to people who Serious stinging X N Annually 250 Competent beekeeper or bee None OHS 85 0f 1993 Sec 8 6 5 0 3 33
Not Rated in 2010

ONPHS down and forming a nest unknowingly or unwarily incidents may (August and removal company
or beehive on building stray into the territory or result, life- September
structures/ trees on site around their nests. threatening injury every year)
and death.
GSR Sec 6,13
HEALTH CR Sec 8; Ekurhuleni

Metropolitan Municipality
EFP001 Personnel / Contractors If personnel have not Seious injury or X A 2m 10 Medical surveillane program, None OHS 85 0f 1993 Sec 8 7 5 0 3 36 48
Public Health By-Laws
ONPHH working at heights been deemed fit to work fatality. upwards.Only Working according to Unilever
published in Local
at heights - can lead to done when working@ heights standards
Authority Notice 1908 of
accident if people there is a need.
23 September 2009
working at heights are
attacked by epiletic GSR Sec 6,13
fit,dizzines etc
CR Sec 8
EFP002 Pushing the full pastrty- Injury to personnel Ergonomical X N 1080kg and the 1 Pallet jack training done.SHE None OHS 85 0f 1993 Sec 8 3 3 0 6 36 36
ONPHH fat pallets from line 1 through slipping and injuries. pallet jack is talks done on proper lifting
using a Pallet Jack. back strain due to only used when techniques
incorrectly pulling and the powered
pushing full pastry pallet pallet truck is
broken down Hygene & ergonomic
Surveys
EFP003 Performing normal tasks Noise could lead to Symptoms of NIHL. X N 86/85 db .Daily 120 Noise surveys, hearing protection None OHS 85 0f 1993 Sec 8 & 5 2 0 9 63 70
ONPHH in Normal working fatigue and lack of exposure to supplied, tea breaks, engineering 14
conditions in new & old concentration which everybody in out where can. Hearing protection
hall (line 1-7) & (line 10- could lead to accident Packing Hall signs posted. PSM survey done
15)
NIHLR Sec 1-14
EFP004 Performing normal tasks Noise could lead to Symptoms of NIHL. X N 86/85 db .Daily 120 Noise surveys, hearing protection None OHS 85 0f 1993 Sec 8 & 5 2 0 9 63 70
ONPHH in Normal working fatigue and lack of exposure to supplied, tea breaks, engineering 14
conditions in new & old concentration which everybody in out where can.Hearing protection
hall (line 1-7) & (line 10- could lead to accident Packing Hall signspostedPSM survey done
15) and not wearing
hearing protection, NIHLR Sec 1-14
exposure to noise which
may lead to NIHL
EFP005 Performing normal tasks Visitors & workers not Loss of hearing. X N 86/85 db.Daily 120 Signage, induction, hearing None OHS 85 0f 1993 Sec 8 & 5 3 0 8 64 64 (T)
ONPHH in Normal working complying to hearing exposure protection supplied, medical 14
conditions in new & old protection rules leading surveilance. Verbal warming
hall (line 1-7) & (line 10- to NIHL Cardinal Rules issued.
15)
NIHLR Sec 1-14
Page 15 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP006 Pushing the rework General use of trolleys Loss of hearing. X N 20 trolleys / per 120 Trolleys been repaired on a None OHS 85 0f 1993 Sec 8 & 2 3 0 8 40 48
ONPHH trolleys in the Packing cause added noise in day by different ongoing basis. System in place to 14
Hall area adding to NIHL employees report defective trolleys, annual
medicals
NIHLR Sec 1-14
EFP007 Performing all normal Fatigue due to heat and Heatstroke or X N 4 months / year 40 Fresh air system in place.Tea None OHS 85 0f 1993 Sec 8 & 2 3 0 9 45 45
ONPHH tasks in the Old-and- this will lead to dehidration. at 35 breaks 14
New-Hall during weariness to employees degrees .Daily
Summer. which will led them to exposure
losing concentration and
thus cause ER Sec 2
accidents/incidents
EFP008 Normal Operation inside Changing of or Sick building X N 1 filter 4 Fillters are cleaned weekly by CC None OHS 85 0f 1993 Sec 8 & 1 1 0 10 20 20
ONPHH the Packaging Hall inadequate changing of syndrome. Airconditioners 14
aircon filters in area
could lead to sinus
problems due to dirt
build up in filters DMR Sec 15
EFP009 Normal use of Steam & Leaks adding noise to Loss of hearing. X N Daily exposure 160 PPE, Engineering maintenance, None OHS 85 0f 1993 Sec 8 & 3 5 0 8 64 72
ONPHH air pipes existing noise levels and to all in the inductions 14
thus may increase the department RHBA Sec 1,2,3,4,6
chances of NIHL
EFP010 Normal use of Steam & Design of machinery Loss of hearing. X N Daily exposure 160 Pneumatic exhaust silencers None NIHLR
OHS 85 0fSec 1-14
1993 Sec 8 & 2 3 0 9 45 45
ONPHH air pipes with lots of pneumatics installed on noisy pistons. Area 14
adding noise to existing classified as noise zone. Refer to
levels Noise survey. PPE.
NIHLR Sec 1-14
EFP011 Manual handling of Improper lifting of Back injury or X N 7 lines/ 25 28 Proper lifting awareness None OHS 85 0f 1993 Sec 8 2 2 0 8 32 32
ONPHH packaging material by wrappers off pallet to skeletal injury. changes per done.Stands erected to facilitate
line-operators. BDR machine could day per line and movement
cause ergonomic strain reels are
to operator different sizes
Hygene & ergonomic
EFP012 Opening or Closing Whilst crawling to open Back injury or X N 4 tanks / only 1 These valves are not used None Surveys
OHS 85 0f 1993 Sec 8 6 3 0 3 27 27
ONPHH Valves under Tank T73- valves for maintenance skeletal injury. when there is a everyday, only during
T76 and under DO tanks employee can strain need maintenance. Valves are used
back due to restricted automatically and fully
area computerised. PPE will be worn.
Hygene & ergonomic
Surveys
EFP013 Normal operation People not using socks Fungicides and X N 12 Hour Shifts 120 Awareness. There is no None OHS 85 0f 1993 Sec 8 & 4 2 0 10 60 60 (T)
ONPHH due to continuous water parasites can and its a daily continuous spillages, but daily 14
spillages causing breed on feet. exposure cleaning. Hose watering not
hygiene risk / incorrect encouraged.
PPE being used
GSR Sec 2
Page 16 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP014 Normal operation of Exposure leading to Serious ill health X N 1 tower. 5 Dosing of chemicals to reduce None OHS 85 0f 1993 Sec 8 & 5 2 0 8 56 63
ONPHH Process Cooling towers disease from legionaires which may lead to Continuously risk, legionnares program. 14
disease death. exposed Regular testing. Exposure is low.
EFP015 Washing of hands before Unclean hands could Spread of diseases X N 2 Entrances / 10 120 Signage, washbays, induction, None OHS 85 0f 1993 Sec 8 & 3 2 0 8 40 40
ONPHH entering plant cause product such as cholerea basins.Daily awareness. Annual training - 14
contamination and &* Typhoid. exposure Comms forums - hand swabs-
spread illness to persons 5S /TPM/new paper dispencers
supplied RHBA
Sec 1,2,3,4,6
GSR Sec 2
EFP016 Floor cleaning – use of Accidental or work- Poisining from X N 25 kg per line / 150 PPE worn by operator, training None OHS 85 0f 1993 Sec 8 & 2 3 0 8 40 40
ONPHH sumachlor related contact or product or serious 10 lines and one point lesson. SOP 14
inhalation of chemical health problems. 7.21.3.11 .Sumaklor, MSDS no.
EWR Sec 6
substances from normal S45
use or spillage
GSR Sec 2,5,7
EFP017 Use of Liquid flavourant Accidental or work- Health problems X N OEL: Not 8 PSM -HCS Survey CMR-73, None OHS 85 0f 1993 Sec 8 & 3 2 0 6 30 30
ONPHH in the flavour room related contact or after long term stated. MSDS no. F27 (non-kosher) & 14
(CMR-73) inhalation of chemical exposure. 10 kg / per F28 (kosher)
substances from normal week HCSR SEC1-17
use or spillage
GSR Sec 2,5,7
EFP018 Use of Liquid Accidental or work- Health problems X N 8 hrs. 10 kg / 8 PSM -HCS Survey - Crearasa, None OHS 85 0f 1993 Sec 8 & 2 5 0 9 63 63 (T)
ONPHH Flavourants in the related contact or after long term per day MSDS no.F.18 14
Flavour room (Crearasa) inhalation of chemical exposure.
substances from normal CR Sec 7(9)
use or spillage HCSR SEC1-17
GSR Sec 2,5,7
EFP019 Use of Liquid Accidental or work- Health problems X N 8 hrs. 10 kg / 8 PSM -HCS Survey TW352-cast, None OHS 85 0f 1993 Sec 8 & 2 5 0 9 63 63 (T)
ONPHH Flavourants in the related contact or after long term per day MSDS no. F.17 14
Flavour room inhalation of chemical exposure.
(TW352-cast) substances from normal CR Sec 7(9)
GSR Sec 2,5,7
EFP020 Caustic pipe leak (LQ3) Accidental or work- Poisining from X N OEL: 2mg/m3 160 Regular maintenance, Safety None OHS 85 0f 1993 Sec 8 & 3 0 0 8 24 24
ONPHH related contact or product or serious 15min STEL (for Showers (liquid, MSDS C.12) 14
inhalation of chemical health problems. NaOH)
substances from normal CR Sec 7(9)
EFP021 Adding ink to Date Coder Accidental or work- Poisining from X N Ink & Solvent: 1 Design of bottle, sealed with foil None OHS 85Sec
GSR 0f 1993
2,5,7Sec 8 & 4 4 0 8 64 64 (T)
ONPHH machine (Linx Marque related contact or product or serious OEL: Butan-2- cap which is only broken once on 14
Ink 1240, Linx Marque inhalation of chemical health problems. one=200ppm- machine, training. All artisans
Solvent 1512) substances from normal 8hr TWA & were trained 29/30 April 03.
use or spillage 300ppm - Disposal drum is in place. CR Sec 7(9)
15min. 500 ml Constant monitoring and GSR Sec SEC1-17
HCSR 2,5,7
per application supervision of this practice.Linx
Marque Ink 1240, MSDS no. L.12
HCSR
CR SecSEC1-17
7(9)
CR Sec 7(9)
Page 17 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP022 Ammonia (Anhydrous) Leaks from gaskets, Eyes-irritation of X N OEL: TLV-TWL 50 PSM -HCS Survey. Ammonia None OHS 85 0f 1993 Sec 8 & 2 4 0 6 36 42
ONPHH used in cooling process draining of machines cornea & tearing 25ppm Anhydrous, MSDS no. A06. 14
during maintenance, worsens with
cleaning process. prolonged
exposure. Skin-
chemical burn & GSR Sec 2,5,7
frostbite. Ingestion-
Toxic &irritant,
heavy
concentrations
fatal. Inhalation- HCSR SEC1-17
Short-term-severe
resp. tract irritant,
Long-term-
irritationof eyes,
nose & upper resp. CR Sec 7(9)
tract.
EFP023 Use / Inserting of Incorrect use of Hearing Loss of hearing. X N Above 85 160 Awareness. Inductions, annual None OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 88
ONPHH Hearing protection protection could cause db.Daily medicals. 14
NIHL exposure
EFP024 Use / Inserting of Contaminated or dirty Could lead to inner X N Daily exposed 1 Clean hearing protection freely None OHS 85 0fSec
1993 Sec 8 & 3 1 0 8 32 40
NIHLR 1-14
ONPHH Hearing protection hearing protection. ear infection. to 89decibels available each day 14
EFP025 Wearing of wet shoes by Getting fungal infections Getting fungal X N 12 Hour 10 PPE Training, Annual Issue of OHS 85 0f 1993 Sec 8 & 2 3 0 8 40 40
ONPHH workers due to working in wet infections due to Shifts.Daily Shoes 14NIHLR Sec 1-14
shoes which are caused working in wet exposure
by contuniously cleaning shoes which are
of flooors using water caused by
contuniously GSR Sec 2
cleaning of flooors
using water
EFP026 Wearing of hair nets by Skin irritation / heat rash Rash of forehead X N 12 hours / day 160 Tea breaks. Investigate probability None OHS 85 0f 1993 Sec 8 & 1 3 0 8 32 40
ONPHH workers due to long periods of with supperficial of issueing permanent "caps". 14
wearing scabbs.
EFP027 Using lifts to transport If the lift door is faulty it If the lift door is X N 2 lifts/12hour 2 Monthly inspection by 3rd None OHS 85 0f 1993 Sec 8 & 5 3 0 8 64 70
GSR Sec 2
ONPHH material can close on its own and faulty it can close shifts party.Lift operators trained. New 14
can cause injuries to on its own and can Lift project
personel taking or cause injuries to
putting materials inside personel taking or
the lift putting materials GSR Sec 2
inside the lift
CR Sec 7(9)
Page 18 of 75 DMR Sec 18

Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP028 Ammonia leaks from Exposure to ammonia. Inhalation to X E OEL: TLV-TWL 25 Emergency plan in place. None OHS 85 0f 1993 Sec 8 & 4 7 0 6 66 70
ONPHH barrels in the Shroeder personnel in area. 25ppm/ 10 litres Ammonia maintanance plan in 14
Inhalation-Short- daily exposure place Emergency
term-severe resp. Procedure 12.6
tract irritant, Long-
term-irritationof CR Sec 7(9)
eyes, nose & upper
resp. tract.
EFP029 Normal Plant operation If work station is not Work-Related Upper X N 4 days / 12 40 TPM AM Tagging. Incident None OHS 85 0f
MHIR Sec1993
1-11Sec 8 3 3 0 8 48 48
ONPHH by Line operators properly designed and Limb Disorders hours per shift Reporting. Ergonomics surveys
the right equipment i.e all equipmenr in done. SHE reps monthly
chairs are not provided the plant inspections
this can lead to back
strains Hygiene & ergonomic
Surveys
EFP030 Normal Plant operation Repetitive operation Repetitive Strain X N 4 days / 12 40 Annual medicals., tea breaks & None OHS 85 0f 1993 Sec 8 3 6 0 8 72 80
ONPHH by Case packer could cause strain, Injuries hours per shift relief on shift
operators fatigue, loss of
concentration
EFP031 Blending operators Repetitive action could Repetitive Strain X N 11 kg – 25 kg 8 Bucket is filled by operator, he can None Hygiene
OHS & ergonomic
85 0f 1993 Sec 8 3 5 0 7 56 63
ONPHH picking up buckets (11 cause back strain Injuries daily exposure control the weight. This has been Surveys
kg to 25kg) walking up observed. No heavy weights are
stairs and pouring into been carried.
tank 11
Hygiene & ergonomic
EFP032 Normal operating Fatigue and monotony Could cause X N 12 hours / 4 160 Tea breaks..Day off None Surveys
OHS 85 0f 1993 Sec 8 4 4 0 8 64 64 (T)
ONPHH conditions work conditions (on / off injury / property days.Daily
work) damage. exposure
EFP033 Lifting reel to feed on the If employees are not Back injury or X N Changed hourly 4 SHE talks & posters on proper n/a OHS 85 0f 1993 Sec 8 4 5 0 9 81 81 (T)
ONPHH machine using the right lifting skeletal injury. in Line 7 & 8.In lifting techniques done Basic Conditions of
techniques whilst lifiting 500g changed Emplyment.
the reels every 45
minutes.
Weights of the Hygene & ergonomic
EFP034 Doing general duties in Employees can be bitten Toxo plasmosis X machines
N Daily are
exposure 160 Rodents trapping.Pest control n/a Surveys
OHS 85 0f 1993 Sec 8 & 14 9 1 0 7 70 70 (T)
ONPHH the plant by rodents ,pests,bees which has serious different.
to all in the done
and cats which are effects in a long plant.Cats can
sometimes found in the run, rabies & be found
plant and if bitten or allergies to bees. outside
touching ,coming in bottling,platform
contact with cat feaces. facing H&K and
lawn next to
canteen
EFP035 Manual stacking of bulk Backstrain due to Repetitive Strain X N Line 1 .Pastry 14 Proper lifting awareness n/a OHS 85 0f 1993 Sec 8 & 14 5 3 0 9 72 80
ONPHH pastry in Line 1 improper lifting and also Injuries weighs done.Operators trained
due to repititive actions 10kg.Operators
rotates and
each at least
stack 8 tons a
day and full
pallet weighs 1
080kg .At least
24 pallets are
Page 19 of 75
packed a day
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP036 General duties Exsesive exposure to Heatstroke or X N Daily exposure 30 Surveys conducted. Medical n/a OHS 85 0f 1993 Sec 8 & 6 1 10 70 70 (T)
ONPHH heat. dehidration. in all EF&P surveilance. SHE Talks. 14
lines.
EFP037 General duties Fatigue which may lead Shift workers X N Daily exposure 30 Rotation of shifts n/a OHS 85 0f 1993 Sec 8 & 14 7 2 0 8 72 72 (T)
ERW Sec 2
ONPHH to injury in all EF&P
lines.
ENVIRONMENT
EFP001 Moving product around Damage to product from Contribute to X N 1000kgDaily n/a Product bonded together by glue Production NEMA Sec 1, 28 (1), (3), 2 3 0 8 40 45
ONPHE the floor using a pallet falling off pallet. landfill. exposure loss 30 (1)a, b,c, (3), (4), (5)
jack.
National Road Traffic

Act Rietfontein
EFP002 Normal use of Steam & Incorrect maintenance Wasteresources:
Wasted of energy X N 10 kW air n/a RCM’s imspections. Trained and None 16/2/7/C221/D49
Environment Conservation 2 3 0 8 40 40
ONPHE air pipes leading to leaks. Non - rework.
Water & energy. compressor, 10 competent Artisans. Act 73 of 1989
reporting of leaks. kW steam
EFP003 Margarine in the Ammonia needs to be Wasted resource: X A 0.5 tons n/a Filters in suction lines on MPU’s None NEMA Sec 1, 28 (1), (3), 5 2 0 4 28 28
ONPHE refrigeration circuit in released – wasted Energy. ammonia 30 (1)a, b,c, (3), (4), (5),
packing hall resource released Environment Conservation
Act 73 of 1989 Sec 19 (1),
A , Ekurhuleni
Solid Waste By-Laws
EFP004 Normal process Depletion of natural Water for cleaning X N 500 tones per n/a Rework system in place, TPM None Regulations relating to 3 3 0 8 48 56
ONPHE resources due to the spill & energy month rework / compulsory national
wastage and for the rework. drain fat standards and measures
reprocessing to conserve water GN R
509 of 8 June
2001National Water Act 36
of 1998 Sec 19, 20, 22,
NEMA Sec 1, 28 (1), (3),
30 (1)a, b,c, (3), (4), (5)
Page 20 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP005 T Tanks process If inlet pipes leaks oil wiill Contamination of X N 4 tanks .Daily n/a Area bunded and drain in that None Regional Standards for 5 3 0 8 64 64 (T)
ONPHE spray into roof and resouce - water. exposure area goes to Rework.If leak industrial effluents GNR
possible ending up in the appers its repaired immediatel 3208 of 29 Aug 1969,
stormwater drains National Water Act 36 of
1998 Sec 19, 20, 22,
NEMA Sec 1, 28 (1), (3),
30 (1)a, b,c, (3), (4), (5),
Water Services Act 108 of
1997 Sec 7(2), 82(1),
Regulations relating to
compulsory national
standards and measures
to conserve water GN R
509 of 8 June 2001,
Boksburg City Councils
Health By-Laws,
Ekurhuleni Metropilitan
Municipality Waste Water
By-Laws
EFP006 Cleaning of factory Floor washings not Contamination of X N 15 m3 n/a Effluent plant control.Cut off None National Water Act 36 of 5 3 0 8 64 64 (T)
ONPHE Floors properly contained in water - Add to floorwasings per drains and when galley is full the 1998 Sec 19, 20, 22,
ground floor (cut off depletion of day sludge gulper is called to pump NEMA Sec 1, 28 (1), (3),
drains) sending fatty resources. sludge out. Daily inspections 30 (1)a, b,c, (3), (4), (5),
water stormwater drains done. Water Services Act 108 of
1997 Sec 7(2), 82(1),
Regional Standards for
industrial effluents GNR
3208 of 29 Aug 1969,
compulsory national
509 of 8 June 2001,
Health By-LawsEkurhuleni
Metropilitan Municipality
Waste Water By-Law
EFP007 Use of pesticides in area Accidental or work- Contributting to the X N Weekly exposed n/a Durban, MSDS No. D.21. None NEMA Sec 1, 28 (1), (3), 3 5 0 5 40 48
ONPHE related contact or disposal of to 1ltr of 30 (1)a, b,c, (3), (4), (5)
inhalation of chemical hazardous waste. dursban
substances from normal
use or spillage .
EFP008 Normal operation of Loss of natural resource Atmmosphiric X N 6m3 / R 5000 n/a Daily inspection by Aldo None n/a 3 3 0 6 36 36
ONPHE MPU through venting pipe pollution & public per m3
(ammonia) nuisance.
Page 21 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP009 Disposal of hair nets Incorrect disposal of nets Overflow of drains X N Blockage once n/a Housekeeping.Environmental None Environment Conservation 2 6 0 8 64 64 (T)
ONPHE down drains causing lead to waste a quarter awareness done.General waste Act 73 of 1989 Sec 19 (1),
blockages to stormwater resource. bins provided A, NEMA Sec 1, 28 (1),
drains (3), 30 (1)a, b,c, (3), (4),
(5)Regulations relating to
compulsory national
EFP010 Ammonia leaks from Incomplete letting-off of Contamination of X N 10 litres 2 Evacuation procedure.Daily to conserve
Inhalation to NEMA Sec 1, water GN(3),
28 (1), R 3 6 0 8 72 80
ONPHE barrels in the Shroeder ammonia could lead to water - Add to checks by 3rd Party 509(1)a,
personnel in 30 of 8 b,c,
June(3),
2001,
(4), (5)
ammonia spill depletion of area Ekurhuleni Metropolitan
resources. Municipality Solid Waste
By-Laws
EFP011 Use of Carboard with a Recycling of cardboard Contributing to X N 9m3 bin / 3 n/a Supervision, demarcated bins, None NEMA Sec 1, 28 (1), (3), 2 2 0 8 32 40
ONPHE lot of offcuts and debris reduced due to unnecessary times a week safety talks, posters, new bin 30 (1)a, b,c, (3), (4), (5),
inappropriate placement landfill. placed at Bottling hall, and Re- Environment Conservation
of bins ethical recyclers on site Act 73 of 1989 Sec 19 (1),
A , Ekurhuleni
Solid Waste By-Laws
EFP012 Disposing of Machine oil Incorrect disposal of oil Contamination of X N 24 litres / n/a Reputable 3rd party contractor None Environment Conservation 4 4 1 4 36 36
ONPHE waste will lead to an soil or water. weekly collects old oil for recycling - Act 73 of 1989 Sec 19 (1),
Environmental impact waste disposal certificates kept at A, NEMA Sec 1, 28 (1),
SHE deparment (3), 30 (1)a, b,c, (3), (4),
(5), Ekurhuleni
Solid Waste By-Laws
EFP013 Contaminated / Incorrcet disposal of Environmental X N Various 1 3rd Party waste removal. Specialy None Environment Conservation 2 3 0 8 40 40
ONPHE redundant or empty contents or container. Precautions: Do containers on a supplied waste containers. Act 73 of 1989 Sec 19 (1),
laboratory materials. not allow to enter monthly basis. A, NEMA Sec 1, 28 (1),
sewerage system. (3), 30 (1)a, b,c, (3), (4),
Incorrect waste (5), Ekurhuleni
disposal. Metropolitan Municipality
Contribute to Solid Waste By-Laws
pollution and Rietfontein
landfill. Water & 16/2/7/C221/D49
soil polution.
EFP014 Contaminated / Incorrcet disposal of Environmental X N Various 1 3th Party waste removal. Specialy None Environment Conservation 2 3 0 8 40 40
soil polution.
Page 22 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
soil polution.
soil polution.
EFP017 Contaminated/redundant Incorret disposal of Environmental X Various 1 3th Party waste removal. Specialy None Environment Conservation 2 3 0 8 40 40
ONPHE or empty laboratory contents or container. Precautions: Do containers on a supplied waste containers. Act 73 of 1989 Sec 19 (1),
materials. not allow to enter monthly basis. A, NEMA Sec 1, 28 (1),
pollution and
landfill. Water &
soil polution.
EFP018 Aircraft movement Passanger plane Fuel and chemical x A 20 000 Litres of 250 Emergency Procedure - 12.6 None Aviation Act, 1962 (Act No. 9 9 0 5 90 96
ONHPE accident/ crash on site Spillages, smoke Jet Fuel 74 of 1962) and the
and Dust Regulations issued in
emissions E terms thereof
EFP019 Normal packing of Poor waste segragation/ Waste ending up in x N 5 -6 wheelie n/a Waste management procedure, None Environment Conservation 4 8 0 6 72
Not Rated in 2010

ONHPE margarine Cross contamination of a landfill - Soil Bins Weekly awareness, Waste Bins provided, Act 73 of 1989,
waste pollution Bins labelled Environment Conservation
Act 73 of 1989 Sec 19 (1),
A, NEMA Sec 1, 28 (1),
(3), 30 (1)a, b,c, (3), (4),
(5), Ekurhuleni
Solid Waste By-Laws
Page 23 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Not Rated in 2010 Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP020 Using hosepipes to clean Excessive water used Depletion of a x N 1000 kl/month 5 Water use Awareness, Install None National Water Act 36 of 4 8 0 8 96
ONHPE factory floors during the cleaning natural resource triggers on all horses 1998 Sec 19, 20, 22,
process NEMA Sec 1, 28 (1), (3),
30 (1)a, b,c, (3), (4), (5),
1997 Sec 7(2),
82(1),Regulations relating
to compulsory national
509 of 8 June 2001,
EFP021 Dairy and Rework plant Pumps failure/ blocked Contamination of x N 1 ton of fats 2 Maintenance in place, Rework None National Water Act 36 of 7 7 0 5 70
Not Rated in 2010

ONHPE operation strainers may lead to roads, stormwater sump, Spill Kits, trained operator, 1998 Sec 19, 20, 22,
excess fat overflow/ drains, Soil Effluent plant NEMA Sec 1, 28 (1), (3),
spillages Pollution 30 (1)a, b,c, (3), (4), (5),
1997 Sec 7(2),
509 of 8 June 2001,
EFP022 Daily use of steam Leaks on steam pipes Wasted resources: x N 250 t/month n/a Daily inspection and fixing of None Environment Conservation 8 8 0 6 96
Not Rated in 2010Not Rated in 2010

ONHPE Water & energy. leaks, awareness Act 73 of 1989
EFP023 Loading of tankers at Oil spillage due to Loss of product, x N 1 ton of oil 2 Trained operators and assistant, None National Water Act 36 of 4 5 0 6 54
ONHPE loading bays Tanker overfill/ Lose Contamination of Clamp on loading pipe, 1998 Sec 19, 20, 22,
loading pipe roads, stormwater Supervision NEMA Sec 1, 28 (1), (3),
drains, Pollution 30 (1)a, b,c, (3), (4), (5),
1997 Sec 7(2),
509 of 8 June 2001,
NON-ROUTINE TASKS
EFP001 NR Cutting knifes Workining on live Serious Injury or X N Every 7weeks 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 5 0 5 45 45
adjustments machinery amputation. Employees. 14
Training (Competent Persons)

GMR Sec 5&6
GSR Sec 2 & CR Sec

7(9)
Page 24 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP002 NR BDR running Workining on live Serious Injury or X N 1 x per month 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 3 6 0 6 54 54
adjustments machinery amputation. Employees. 14

GMR Sec 5&6
EFP003 NR BDR ejector Handling of heavy Back strain, Injury X N 1 x every 6 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 4 0 5 40 40
replacement/repairs machine parts or Amputation. months Employees. 14GSR Sec 2 & CR Sec
7(9)

GMR Sec 5&6
EFP004 NR Jaws adjustments Manual rotation causing Fingers could get X N 1 x per month 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 6 5 0 8 88 88
nip & pinch points. pinched causing Employees. 14
fractures or
amputations.
GMR Sec 5&6
EFP005 NR Chain tensioning Work with hand tools Cut on hands and X N 1 x every 6 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 4 0 9 72 72
fingers. months Employees. 14

GMR Sec 5&6
EFP006 NR Proportioning pump cup Lifting of heavy Back strain, Injury X N 1 x every 3 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 3 5 0 6 48 48
GSR Sec 2 & CR Sec
seals replacements equipment + use off or Amputation. months Employees. 14
7(9)
handtools

GMR Sec 5&6
Cut on hands and

fingers.
EFP007 NR HP pump cupseals Lifting of heavy Back strain, Injury X N 2 x every 3 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 6 6 0 4 48 48
replacements equipment + use off or Amputation. months Employees. 14GSR Sec 2 & CR Sec
handtools 7(9)

GMR Sec 5&6
EFP008 NR Pasteurizer plates Heat & handtools Cut on hands and X N 1 per year 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 3 6 0 7 63 63
replacements fingers. Employees. 14

GMR Sec 5&6
Burn with hot

surfaces.
GSR Sec 2 & CR Sec

7(9)
Page 25 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP009 NR Unitator/Schroeder A- Heavy machine parts & Back strain, Injury X N 1 x 3months 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 5 5 0 7 70 70
units blades exposure to ammonia or Amputation. Employees. 14
inspection/replacements gas

GMR Sec 5&6
Exposure to
Ammonia
EFP010 NR Unitator/Schroeder Lifting of heavy Back strain, Injury
(Asphyxiation) X N 1 x every 6 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 4 0 4 32 32
Mechanical seals equipment + use off or Amputation. months Employees. 14GSR Sec 2 & CR Sec
replacements handtools 7(9)

GMR Sec 5&6
Cut on hands and

fingers.
EFP011 NR Unitator/Schroeder Lifting of heavy Back strain, Injury X N 1 x per year 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 5 0 5 45 45
bearings replacements equipment + use off or Amputation. Employees. 14GSR Sec 2 & CR Sec
handtools 7(9)

GMR Sec 5&6
Cut on hands and

fingers.
EFP012 NR Unitator/Schroeder shaft Hot water/Hand tools Cut on hands and X N 1 x every 6 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 2 8 0 7 70 70
heating repairs fingers. months Employees. 14GSR Sec 2 & CR Sec
7(9)
GMR Sec 5&6
Burn with hot water

65° - 70°
EFP013 NR Unitator belts Nip points & Handtools Fingers could get X N 1 x per year 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 3 3 0 5 30 30
replacements Lifting heavy equipment. pinched causing Employees. 14GSR Sec 2 & CR Sec
fractures or 7(9)
amputations.
GMR Sec 5&6
Back
strain.
EFP014 NR Unitator/Schroeder Exposure to ammonia + Cut on hands and X N 1 x every 3 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 3 0 7 49 49
PSV's maintenance use off handtools fingers. years Employees. 14GSR Sec 2 & CR Sec
7(9)

GMR Sec 5&6
Exposure
to Ammonia
(Asphyxiation)
GSR Sec 2 & CR Sec

7(9)
Page 26 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP015 NR Shaft heating water Hot water 65°-70° & Cut on hands and X N 1 every 2 years 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 4 0 6 48 48
element replacement Handtools fingers. Employees. 14

GMR Sec 5&6
Burn with hot water

65° - 70°
EFP016 NR Unitator/Schroeder Lifting of heavy motors - Fingers could get X N 1 x every 6 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 5 5 0 4 40 40
motors replacements 200Kg+ pinched causing months Employees. 14GSR Sec 2 & CR Sec
fractures or 7(9)
amputations.
GMR Sec 5&6
Back
strain.
EFP017 NR Hamba lid station Moving machinery Serious Injury or X N 1 x weekly 1 Lock out procedure New GSR
OHS 85Sec 2 & CR
0f 1993 SecSec
8& 7 5 0 8 96 96
adjustments amputation. Employees. 7(9)
14

GMR Sec 5&6
EFP018 NR Maching timing Moving machinery Serious Injury or X N 1 x every 2 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 7 0 5 55 55
adjustments amputation. weeks Employees. 14GSR Sec 2 & CR Sec
7(9)
GMR Sec 5&6
EFP019 NR Product change-overs Lifting heavy machine Fingers could get X N 1 x weekly 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 7 0 8 88 88
parts and moving pinched causing Employees. 14
machinery fractures or GSR Sec 2 & CR Sec
amputations. 7(9)
GMR Sec 5&6
Back
strain.
EFP020 NR Case packer settings Hand tools & ergonomics Cut on hands and X N 1 x weekly 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 4 0 4 32 32
adjustments fingers. Employees. 14GSR Sec 2 & CR Sec
7(9)

GMR Sec 5&6
GSR Sec 2 & CR Sec

7(9)
Page 27 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP021 NR Welding Electricution, Fire and Electricution, srious X N 1 x monthly 1 Lock out procedure New OHS 85 0f 1993 Sec 8 & 4 6 0 4 40 40
fumes burn & respitory Employees. 14
problems from the
fumes.
GSR Sec 2 & 9
EFP022 NR Loading materials onto Unstable pallets with Head or serious X N 1 x monthly 10 Weekly checks on scaffolding. None OHS 85 0f 1993 Sec 8 & 7 8 0 4 60 60
scaffolding material can topple over other injuries. New Lift Project 14 CR Sec 7(9) & 27(f)
– injure surrounding
persons
DMR Sec 2
EFP023 NR Loading of materials Person can be blinded Head or serious X N 1 x monthly 10 Weekly checks on scaffolding. None OHS 85 0f 1993 Sec 8 & 7 8 0 4 60 60
onto scaffolding by the sun and miss the other injuries. New Lift Project 14 GMR Sec
scaffolding . Palllets can 1,2,3,4,5,6,7,8,9,10
fall and injure a person
DMR Sec 2
INCIDENTS
NI-2008/09 Use of Chemical Water with Sumaklor Loss of eye sight. X N 500gr 3 X per 1 Inductions, P.P.E, Hazrdous Accidental GSR
OHS 85 Sec 8 Sec 8 &
0f 1993 3 6 0 5 45 45
Hazardous substances powder got into the eyes week Chemical Assements poisining of 14
the operator.
HCS Sec
3,4,7,9,9A,10,11-16
NI-2008/10 Changing a forklift Hand collided with the Injury to the hand X N 3 X per week 1 Licensed & trained forklift drivers. Battery OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 80
battery Forklift Battery Cover or even amputation (Trained hoist operators) could fall on 14
of finger(s) foot. Battery
could fall
onto the
ground DMR Sec18
(Explode or
leak battery
acid)
GSR Sec 6,13

NI-2008/12 Machine settings Whilst turning the BDR Cut on the right X N 3 X per week 1 Training (Competent Persons) New OHS 85 0f 1993 Sec 8 & 2 8 0 8 80 80
the employee sustained finger personnel. 14
a cut on his right index
second knuckle.
GMR Sec 5
NI-2008/13 Cleaning the machine The employee was Cut on the finger X N Daily 1 Training & PPE issue. Infections OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 80
cleaning the machine 14
with out gloves when a
sharp edge cut his
finger.
GSR Sec 3
Page 28 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI-2008/17 Sorting and Wrapping Forklift drivers not Forklift rolled over X N Daily 1 Licensed & trained forklift drivers. Property OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 80
pallets following the the foot SHE Talks and awareness. damage. 14
dismounting procdure of
forklift. No engaging of
the hand brake.
DMR Sec18
NI-2008/18 Use of Metal Ruler Sharp metal rulers or Three fingers got X N Daily 1 Induction, P.P.E, Hand Tool Infections OHS 85 0f 1993 Sec 8 2 5 0 7 49 49
sharp tools and cut Inspections & Training
instruments.
NI-2008/19 Cleaning of Linx Ink accidentally got into Loss of eye sight. X N Daily 1 Induction, P.P.E & Training Poisoning by OHS 85 0f 1993 Sec 8 & 3 7 0 7 70 70
Machine (Removing of the eyes accidental 14
ink from the Date Coder contact.
lines)
HCS Sec
3,4,7,9,9A,10,11-16
NI-2008/20 Cleaning of Tanks in the The glove got torn and Chemical burn the X N Daily 1 Induction, P.P.E & Training Poisoning by OHS 85 0f 1993 Sec 8 & 2 7 0 7 63 63
Dairy Plant with the cleaning chemical right thumb. accidental 14
chemicals. burnt the right thumb contact.
HCS Sec
3,4,7,9,9A,10,11-16
NI-2008/23 Discarding of Hazardous Inhaled ink in the dustbin Employees with X N Daily 1 Induction, Training & Supply of Poisoning by OHS 85 0f 1993 Sec 8 & 7 7 0 8 ### 112
Waste incorrectly. asthma could be Hazardous waste containers. accidental 14
affected by sharp contact.
chemical odour.
People can get
sick or poisoned. HCS Sec
Contamination of 3,4,7,9,9A,10,11-16
all other general
waste.
NI-2008/24 Employee was was Exposure to Ammonia. Respiratory X N Very small 1 Maintenance on all ammonia Staff who GSR
OHS 85 0f 1993 Sec 8& 4 7 0 6 66 66
exiting the EF&P plant difficulty. quantity. ± 20mg vessels and pipe lines. suffer from 14
when she inhailoed asthma.
amonia.
HCS Sec
3,4,7,9,9A,10,11-16
NI-2008/25 Employee was busy Use of sharp hand tools Cut sustained to X N Daily exposure. 1 Issue of PPE and induction Failure to OHS 85 0f 1993 Sec 8 & 3 5 0 7 56 56
cutting loose pallets to perform tasks. the feft index training. wear PPE. 14
when she accidently cut finger.
herself with a stanley
knife.
GSR Sec 2
NI-2008/26 Incorrect electrical Flourescent light Serious injuries or X N Rarely 1 Competent Electrician Contractor. Sub OHS 85 0f 1993 Sec 8 7 4 0 3 33 33
installations. overheated in the CIP even death. Standard
room and casued fire Equipment.
Inexperience
Approved Inspection Authorities. d contractors
and failure to EIR Sec 2,3
follow
drawings.
EMR Sec 1,2,6,13
Page 29 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI-2008/27 Tubs Line Packing Left pinkie finger caught Serious injury to X N Daily on most 1 Machine guards. Loose OHS 85 0f 1993 Sec 8 & 6 9 0 6 90 90
(Removing of jammed in the moving conveyor hand or fingers. machines machine 14
Tubs & Lids from the whilst removing tub form Amputation of guards &
Hamba Conveyors) the conveyor finger tips. unidentified
Learnership training. areas.
GMR Sec 5&6
SHE Awareness and Inductions.

NI-2008/28 Cleaning of P-Body with Burnt by hot water 65° Hot water entered X N Daily cleaning of 1 Inductions, P.P.E,Internal New or OHS 85 0f 1993 Sec 8 & 5 5 0 6 60 60
hot water. the employees the Dairy and learnerships Temp 14
s/shoe. other areas employees.
NI-2008/31 Ergonomics Failing to use lifting Sprained X N 5 X per week 1 Ergonomic surveys, Training on Serious OHS 85 0f 1993 Sec 8 & 7 7 0 8 ### 112
equipment which is neck/back while safe lifting techniques. muscular 14
provided. picking up ±25kg and skeletal
bag injuries
NI-2008/32 Cleaning Sumaklor powder Loss of eyesight X N 500gr 3 X per 1 Inductions, P.P.E, Hazardous Accidental OHS 85 0f 1993 Sec 8 & 3 6 0 5 45 45
splashed into eyes whilst could have been week Chemical Assessments poisining of 14
mixing it with water in a the outcome. the operator.
trolley using a jar
HCS Sec
NI-2009/01 Loose Solanoid valve The ammonia leak Burning eyes, X N Daily exposed 3 Weekly checks on Unitators Respiratory OHS 85 0f 1993 Sec 8 & 2 8 0 4 40 40
due to machine affected operators at painful chest and to Unitators Difficulties 14
vibrations mezannine floor nausea
Sulphur stick weekly usage
to detect leaks
HCS Sec
NI-2009/01C Cleaning of pipes The Contractor was Small cut ±1cm X N Quarterly 1 None OHS 85 0f 1993 Sec 8 & 2 8 0 6 60 60
cleaning pipelines when 14
he got cut on the arm by
a pipe clamp.
NI-2009/02 Loose Solenoid valve The ammonia leak Burning eyes, X N Daily exposed 3 Weekly checks on Unitators Respiratory OHS 85 0f 1993 Sec 8 & 2 8 0 4 40 40
to detect leaks
HCS Sec
NI-2009/02C Fitting new light bulb While removing scaffold, X N Monthly 1 Training. None OHS 85 0f 1993 Sec 8 2 5 0 4 28 28
the Contractor hit the
open light and the globe
hit him in the face.
GSR Sec 6,13

NI-2009/03 Loose Solenoid valve The ammonia leak Burning eyes, X N Daily exposed 3 Weekly checks on Unitators Respiratory OHS 85 0f 1993 Sec 8 & 2 8 0 4 40 40
to detect leaks
HCS Sec
NI-2009/03C Cleaning of offices Employee was cleaning Small cut ±1cm X N Daily 1 Induction. PPE OHS 85 0f 1993 Sec 8 & 2 5 0 8 56 56
when a broken picture 14
frame glass cut her
finger.
Page 30 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI-2009/04 Working on the A Frame Fingers pressed due to Small cut ±1cm X N Daily 1 Machine guards. Serious OHS 85 0f 1993 Sec 8 & 1 8 0 8 72 72
Feeder pressure from lids skeletal 14
injuries
GMR Sec 5&6

NI-2009/04C Removing charging lines The Contractor was X N Monthly 1 Training. PPE. Pre-maintenance None OHS 85 0f 1993 Sec 8 & 7 3 0 4 40 40
on aircon removing the charging Inspection checklist. 14
lines without closing the
valves properly.
NI-2009/05 Travelling on company 4 car pile accident Whiplash X N Daily 1 Safe Travel Policy Serious OHS 85 0f 1993 Sec 8 & 5 7 0 8 96 112
business Defensive muscle and 14
Driving Training skeletal
injuries
NI-2009/05C Using a grinder Whilst using a grinder, 1cm laceration X N Monthly 1 Training. PPE. None OHS 85 0f 1993 Sec 8 & 2 8 0 6 60 60
the employee sustained 14
1cm laceration on the
(RT) wrist
EMR 1 & 11
NI-2009/06 Working on the glue pot Burnt by glue whilst Minor burns on the X N Daily 1 Induction. PPE None OHS 85 0f 1993 Sec 8 & 1 10 0 8 88 88
trying to remove paper hand 14
(packaging for the glue)
that was blocking the
nozzle
HCS Sec
3,4,7,9,9A,10,11-16
NI-2009/06C Working near hot The Contractor Minor burns on the X N Daily 1 Induction. PPE None OHS 85 0f 1993 Sec 8 1 8 0 8 72 72
surfaces accidentally put her hand
hand on the warmer, GSR
unaware that it is hot Sec 2
ERW Sec 1
NI-2009/07 Walking pass Security Stood in an open Fractured ankle X N Daily 430 Work Permit Procedure None OHS 85 0f 1993 Sec 8 & 1 5 0 8 48 48
Gate 8 manhole 14
CR
Sec 7(9)
NI-2009/07C Cleaning of pipes The Contractor was Small cut ±2cm X N Monthly 1 Training. PPE. None OHS 85 0f 1993 Sec 8 & 2 8 0 6 60 60
cleaning pipelines when 14
he got cut on left ring
finger by a pipe clamp.
NI-2009/08 Opening of raw materials The employee was Small cut ± 1cm X N Daily 1 Training. PPE None GSR
OHS Sec
85 0f21993 Sec 8 & 2 9 0 9 99 112
bags using Stanley knife opening bags when he 14
accidentally cut himself
with a Stanley knife
CR Sec 7(9)
NI-2009/08C Cleaning of floors The Contractor was Sustained a sprain X N Daily 1 Induction. Handrails provided. Fall None OHS 85 0f 1993 Sec 8 2 8 0 8 80 80
carrying a water bucket Prevention
going down the steps
when he missed a step
with his left foot formed
over. GSR Sec 2
Page 31 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI-2009/09 Employee was busy Use of sharp hand tools Cut sustained to X N Daily 1 Induction. PPE Serious OHS 85 0f 1993 Sec 8 & 3 5 0 8 64 64
opening bags when he to perform tasks. the left index skeletal 14
accidently cut himself finger. injuries
with a Stanley knife.
NI-2009/09 Employee was making Handling of Hazardous The solution X N Daily 1 Induction. PPE Serious eye OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 104
up Citric Acid Solution in Chemicals splashed into the injuries / 14
a tank right eye when a blindness
lump went into the
tank
HCS Sec
NI-2009/09C While loosening a bolt Use of hand tools to Sustained a sprain X N Monthly 1 Training.PPE None OHS 85 0f 1993 Sec 8 & 2 5 0 6 42 42
nut a spanner slipped perform tasks. 14
and my hand hit against
the steel
GMR Sec 5&6

NI-2009/10C When removing the Use of hand tools to Sustained a sprain X N Monthly 1 Training. PPE None OHS 85 0f 1993 Sec 8 & 2 8 0 6 60 60
shelve the driff bounced perform tasks. 14
out of the hand and hit
the contractor on the
forehead on the orbit left
eye GMR Sec 5&6
NI-2009/11 Employee was cleaning Burnt by hot water The employee was X N Daily 1 OPL. Trigger Control nozzle Serious OHS 85 0f 1993 Sec 8 & 2 9 0 8 88 112
the floor using a hosepie burnt by hot water burns 14
GSR Sec 2 & CR Sec
when there was a kink in on the face and
7(9)
the hosepipe which neck
resulted in a snake effect
GMR Sec 5&6
NI-2009/11C Employee was cleaning Burnt by hot water The employee was X N Daily 1 OPL. Trigger Control nozzle Serious OHS 85 0f 1993 Sec 8 & 2 9 0 8 88 88
the platform with a burnt by hot water burns 14GSR Sec 2 & CR Sec
hosepipe using hot on the face 7(9)
water. The hosepipe
twisted.
GMR Sec 5&6
NI-2009/12 Employee was opening a Burnt by steam Injuries X N Daily 1 Training. PPE.OPL. Serious OHS 85 0f 1993 Sec 8 & 2 8 0 6 60 60
valve when he was burnt burns 14
by steam from the
slightly opened buffer GSR Sec 2 & CR Sec
tank lid 7(9)
ERW Sec 6
NI-2009/12C Walking down the stairs Missed a stair and Twisted ankle X N Daily 1 Handrails provided. None OHS 85 0f 1993 Sec 8 & 2 8 0 8 80 80
slipped 14
GMR Sec 5&6
Page 32 of 75
GSR Sec 2 & CR Sec
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI-2009/13 Overflow of Rework Tank Employee walking Sprain on the left X N Daily exposed 1 Training.OPL.Housekeeping.SOP Fracture OHS 85 0f 1993 Sec 8 4 6 0 6 60 60
between Line 6 and 7 hand to Rework tank
when he slipped and fell
GSR Sec 2
Industrial Effluent
NI-2009/13C Employee was stripping Hit by crowbar injury on the left X N Daily 1 Training, PPE, Induction None Discharge
OHS 85 0f Permit
1993 Sec 8 & 2 5 0 6 42 42
wood shutter when a pinkie finger 14
crowbar slipped and hit
his left pinkie against the
wall
GMR Sec 5&6
NI- Unblocking the husk Slipped and fell on his Bruise, Cuts/ Back X N Daily 1 Training. SOP None OHS 85 0f 1993 Sec 8 & 2 8 0 8 80
Not rated in 2010 Not rated in 2010 Not rated in 2010

2010/01UL feeder. back injuries 14
GSR Sec 2 & CR Sec

7(9)
GMR Sec 5&6
NI- Opening the supply Possible Ammonia leak Suffered X N Only done when 4 Procedure for working on a None OHS 85 0f 1993 Sec 8 & 2 7 0 9 81
2010/02UL valve for ammonia liquid Asphyxiation/ there is a need unitator. Training 14
during start up in the Dizziness
pilot plant.
GSR Sec 2
NI- Changing mechanical Upon removing the Ammonia X N Only done when 4 Procedure for working on a None OHS 85 0f 1993 Sec 8 & 2 8 0 8 80
2010/03UL seal on MPU 8 - Line 11. dome, the flange may inhalation, there is a need unitator. Training 14
collapse thus releasing Asphyxiation
ammonia
GSR Sec 2
NI- Cleaning the floor whilst Sigh glass busting, Hot Burns on face and X N Once a week 6 SOP for Glass and Plastic Serious eye OHS 85 0f 1993 Sec 8 & 4 8 0 6 72
Not rated in 2010 Not rated in 2010 Not rated in 2010

2010/04UL CIP is running. water splashing into foreign body in the Handling. Training injuries / 14
eyes and face eyes blindness CR Sec 7(9)
HCS Sec
3,4,7,9,9A,10,11-16
NI- Using a Stanley knife to Blunt Stanley knife Sustained a sprain X N Weekly 2 OPL. New Wilkinson paring None DMR85Sec
OHS 18 Sec 8 &
0f 1993 2 5 0 6 42
2010/05UL cut plastic strapping that knives. 14
fastens Flora boxes
GMR Sec 5&6
NI- Using a forklift to pull out Pallets breaking into Foreign bodies in X N Daily 1 Supplier to make None OHS 85 0f 1993 Sec 8 & 2 8 0 8 80
2010/06UL pallets from the rug in half, wood pieces and the eyes 14
the cold room saw dust falling
GMR Sec 5&6
Page 33 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Not rated in 2010 Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI- Normal day to day Possible Ammonia Ammonia X N Done during 30 Barricades, Warning signs, None OHS 85 0f 1993 Sec 8 & 6 7 0 5 65
2010/07UL working in the lab release from the pipes inhalation, shutdown Awareness 14
building when Asphyxiation
maintenance work is
taking place in the
refrigeration plant GMR Sec 5&6
NI- Normal day to day Possible Ammonia Ammonia X N Done during 30 Barricades, Warning signs, None OHS 85 0f 1993 Sec 8 & 6 7 0 5 65
Not rated in 2010

2010/08UL working in the lab release from the pipes inhalation, shutdown Awareness 14
building when Asphyxiation
maintenance work is
taking place in the
refrigeration plant GMR Sec 5&6
NI- Walking down the stairs Uneven surfaces Injury to the foot, X N Monthly 120 Demarcations, Warning signs, None OHS 85 0f 1993 Sec 8 & 2 8 0 8 80
Not rated in 2010 Not rated in 2010 Not rated in 2010Not rated in 2010 Not rated in 2010
2010/09UL when construction twisting ankles Alternative routes, toilets and Tea 14
activities are taking place Bays to be used
in the EF&P
GMR Sec 5&6
NI- Pouring caustic soda into Caustic soda splash injury to the eye X N Weekly 1 SOP, PPE None OHS 85 0f 1993 Sec 8 & 6 8 0 6 84
2010/10UL a tank in the pilot plant and burns on the 14
face
GMR Sec 5&6

NI- Fitting or changing Caustic release during Injuries to the X N Monthly 4 Warning signs, Water routed None OHS 85 0f 1993 Sec 8 & 4 5 0 5 45
2010/11UL pumps in the Dairy plant CIP knee, burns directly into drains 14
GSR Sec 2 & CR Sec

7(9)
GMR Sec 5&6
NI- Removing stack cap Capping starwheel out of Finger injuries X N Monthly 2 SOP, OPL None OHS 85 0f 1993 Sec 8 & 2 8 0 5 50
2010/12UL between the cap plate in timing 14
the starwheel at Lipton GSR Sec 2 & CR Sec
Ice Tea 7(9)
GMR Sec 5&6
NI- Changing swing band on Use of hand tools to Finger injuries X N Monthly 1 Training.PPE None OHS 85 0f 1993 Sec 8 & 2 5 0 6 42
2010/13UL Line 2 perform tasks. 14
GSR Sec 2 & CR Sec

7(9)
GMR Sec 5&6
GSR Sec 2 & CR Sec

7(9)
Page 34 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI- Walking down the stairs Fatigue due to lack of Sprained foot X N Daily 2 Training None OHS 85 0f 1993 Sec 8 & 2 4 0 7 42
2010/14UL during night shift rest 14
GMR Sec 5&6
NI- Walking past rework Holes on the floor Sprained foot X N Daily 20 Supervision, correct safety None OHS 85 0f 1993 Sec 8 & 3 6 0 8 72
2010/15UL area barriers 14
GSR Sec 2 & CR Sec

7(9)
GMR Sec 5&6
NI- Using hammer and Taking an unsafe Hit by hammer - X N weekly 1 Awareness, Training, Pre job None OHS 85 0f 1993 Sec 8 & 3 8 0 6 66
2010/16UL punch to remove position finger injuries inspection and planning 14
gearbox shaft
GSR Sec 2 & CR Sec
7(9)
GMR Sec 5&6
NI- Walking down the stairs Steep stairs Trip and fall - N Daily 20 Awareness, re -design stairs None OHS 85 0f 1993 Sec 8 & 2 4 0 7 42
2010/17UL at stores exit injuries 14
GSR Sec 2 & CR Sec

7(9)
NI- Removing pallets from Sharp pieces of wood Possible entry into X N Daily 1 PPE, Procedure None OHS 85 0f 1993 Sec 8 & 3 8 0 6 66
2010/18UL the material materials on the pallet the palm/ fingers 14
GSR Sec 2
& CR Sec 7(9)
GMR Sec 5&6
Ni-2011/01 Replacement of a drive Use of an incorrect tool HIt by hammer X N When there is a 1 Awareness, Training, Pre job None OHS 85 0f 1993 Sec 8 & 1 5 0 3 18
belt on a reduction to remove the shaft need inspection and planning 14
gearbox
GSR Sec 2 & CR Sec
7(9)
Ni- 2011/02 Cleaning of the Date Solvent Spillage Can cause harm if X N When there is a 1 Awareness, Training None OHS 85 0f 1993 Sec 8 & 6 2 0 5 40
Coder it comes in contact need 14
with any part of the GSR Sec 2
body & CR Sec 7(9)
HCS Sec
3,4,7,9,9A,10,11-16
Ni- 2011/03 Servicing of the Case Hot Glue Can cause burns X N Monthly 1 Awareness, Training None OHS 85 0f 1993 Sec 8 & 2 3 0 5 25
Packer 14
GSR
Sec 2
HCS Sec
3,4,7,9,9A,10,11-16
Page 35 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Not rated in 2010 Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI-2011/04 Seperation of Steel Steel Hand Injury X Twice a year 1 Awareness; PPE None OHS 85 0f 1993 Sec 8 & 1 3 0 3 12
Buckets 14 GSR Sec 2
Ni- 2011/06 Running of the Filler Moving machinery Can cause injury X N When there is a 1 Safety Guards None OHS 85 0f 1993 Sec 8 & 1 3 0 10 40
Machine need 14
Ni-2011/07 Fixing the hot water leak Hot water Can leak and X N When there is a 1 OPL None OHS 85 0f 1993 Sec 8 & 1 5 0 5 30
cause burn need 14 GSR Sec 2 & CR Sec
7(9) GSR Sec 2
& CR Sec 7(9)
Ni-2011/08 Transporting goods with Moving machinery Can cause injury X N Daily 1 OPL None OHS 85 0f 1993 Sec 8 & 1 3 0 9 36
the Pallet Jack 14
GMR Sec 5&6
Ni-2011/09 Repairing of the Valve Working on Hot Surfaces Can cause burns X N When there is a 1 Awareness; PPE; Signage None OHS 85 0f 1993 Sec 8 & 1 3 0 5 20
need 14
GSR Sec 2 & CR Sec

7(9)
Ni-2011/10 Repairing of the Heat Working with Hand Tools Can cause injury X N When there is a 1 Awareness; PPE; Signage None OHS 85 0f 1993 Sec 8 & 1 2 0 5 15
Exchangers need 14
GSR Sec 2 &
CR Sec 7(9)
Ni-2011/11 Removal of jammed Moving machinery Can cause injury X When there is a 1 Safety Guards; Training None OHS 85 0f 1993 Sec 8 & 1 2 0 5 15
bottle from the machine need 14
GSR Sec 2 &
CR Sec 7(9)
NI- Transporting of Steel Bins Bumped his face X A When there is a 1 Awareness, use the Forklift to None OHS 85 0f 1993 Sec 8 & 1 2 0 1 3
2011/12UL Bins need carry the packaging material to 14
the Line GSR Sec 2 &
CR Sec 7(9)
GMR Sec 5&6
Page 36 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
NI- The was a steam leak Steam Burns injury X N Frequently Schedule Preventative None OHS 85 0f 1993 Sec 8 & 3 9 0 4 48 36
2011/13UL that flooded the Maintanance on for all crical 14
mezzanine floor and isolation valves
resulted in some
packaging material being
damaged GSR Sec 2,5,7
NI- The employee was Lifting of the material Bumped his face X A When there is a 1 Awareness, use the Forklift to None OHS 85 0f 1993 Sec 8 & 1 2 0 1 3
Not rated in 2010

2011/14UL taking the packaging need carry the packaging material to 14
material to the Line the Line
HCSR SEC1-17
GMR Sec 5&6
NI- The was a steam leak Steam Burns injury X N Frequently Schedule Preventative None OHS 85 0f 1993 Sec 8 & 3 9 0 4 48 36
2011/13UL that flooded the Maintanance on for all crical 14 MHIR Sec 1-10
mezzanine floor and isolation valves
resulted in some GSR Sec 2 & CR Sec
packaging material being 7(9)
damaged GSR Sec 2,5,7
HCSR SEC1-17
MHIR Sec 1-10
Page 37 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LESSON'S LEARNT
LL001SA Caustic Burns Accidental or work- LTA X N 1 1. Caustic to be flushed None OHS 85 0f 1993 Sec 8 & 4 6 0 4 40 40
related contact or immediately with water when in 14
inhalation of chemical contact with skin.
substances from normal 2. Not to
use or spillage kneel on wet platforms
HCS Sec
3,4,7,9,9A,10,11-16
3.Ensure that MSDS is
understood and/or implications
thereof before working with any
acid
LL002SA Operating machine Finger injury caught LTA X N 1 1. People should not work in moving 4. None OHS 85 0f 1993 Sec 8 & 6 9 0 8 ### 120
between sprocket and machinery 14
chain 2. Proper training to all new
employees
3. Ensure that all rotating machinery
(sprockets and pulleys) must be GMR Sec 5&6
guarded
LL003SA Electrocution Electric Shock MCC LTA X N 1 1. Medical and 1st aid at MCC to be None OHS 85 0f 1993 Sec 8 6 9 0 8 ### 120
reviewed in line with Unilever
Standards.
2. Always follow procedures (Lock
out Procedure in this case)
3. Risk Assessments on routine tasks EIR Sec 2,3
not properly conducted and
documented.
4. Clarify Isolation vs. Lock Out
Procedures ( as well as exceptions)
5. All Electrical SOP’s and Annual EMR Sec 1,2,6,13
sign off to be audited regularly
(include other SOP’s Engineering &
Production
SANS 0142
LL004SA Moving Machinery Finger caught in moving LTA X N 1 1. Safety switches all removable None OHS 85 0f 1993 Sec 8 & 6 9 0 8 ### 120
machinery machine guards on the Fuji machines 14
must be installed.
2. Review of all guards on the Fuji
3. Investigate the option of preventing GMR Sec 5&6

the cello from falling between the bar
chain.
Page 38 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL005SA Slipping Slipped and sprained RWC X N 1 1.General awareness of surroundings None OHS 85 0f 1993 Sec 8 6 4 0 8 80 80
ankle needs to be improved.
2.External conditions (e.g.bird
droppings )needs to be factored in
Risk assessments.
3.Hand –rails and staircases need to GSR Sec 2
be reviewed.
LL006SA Operating machine Hand caught in mixer RWC X N 1 1. Understanding process None OHS 85 0f 1993 Sec 8 & 6 9 0 8 ### 120
specifications, and the difference 14
between guards and grids
LL007SA Operating machine Finger caught in the MTC X N 1 Awaiting Lesson's Learnt None OHS 85 0f
GMR Sec1993
5&6Sec 8 & 6 9 0 8 ### 120
conveyor 14
LL008-12SA Safe Travel Motor vehicle accidents Minor X N Daily exposure 1 Be prepared to relinquish your None OHS 85 0f 1993 Sec 8 & 6 2 0 8 64 64
by all staff. right of way. Remember you have 14
GMR Sec 5&6
no control over the actions of
other road users but you certainly
can influence it by your positive
attitude and actions. Maintain a National Road Traffic
Safe Following distance between Act
your vehicle and the vehicle in
front.Be aware of your
surroundings – you do not have to
be wrong to be involved in an CR 7(9)
accident. Unilever employees
must practice the following Safe
Travel techniques:
1. Take frequent breaks on long
trips and do not drive when you
know you are fatigued
2. Maintain proper following
distances and be aware of your
surroundings, especially in areas
where roadways converge
3. Take your time, don’t
compromise on safety.
Look in front of you when driving
forward, especially when doing so
from a stationary position.
1. Be conscious of your
surroundings, especially if you are
feeling rushed, even marginally.
2. Do not assume what other road
users will do – always confirm that
you know what their actions are.
3. Take your time, don’t
Page 39 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL001SA Tunnel fire from use of Failure to follow safe Fire X E Rarely 1 1. Safe Operation procedures None OHS 85 0f 1993 Sec 8 & 2 8 0 1 10 10
angle grinder to cut operating procedures must be followed at all times. 14
metal pin - this caused a and hotwork permit. 2. Hot Work Permits needs to be
piece of hot rod to fall Inadequate enforced when conducting any
onto plastic conveyor Supervision. Hot Work.
and ignited Inadequate training, 3. No grinding or cutting near EMR 1 & 11
instruction and materials that are highly
orientation combustible.
4. Emergency
LL002SA Sales office motor Routine, LTA X N Daily 1 Procedure
1. be more 12.6
vigilant on the road None DMR
OHS 85Sec 8
0f 1993 Sec 8 & 6 3 0 8 72 72
vehicle accident, monotomy,demand for and observe activities around you. 14
employee collided with a uneventful vigilance. 2. Be conscious of
3rd party and sustained Lack of Situational your surroundings, especially if
soft tissue damage to Awareness you are feeling rushed, even
neck marginally. National Road Traffic
3. Do not assume what Act
other road users will do - always
confirm that you know what their
actions are.
4. Take your time, don't CR 7(9)
5.
Do not admit guilt at time of
incident, await internal
investigation team to assist
LL003SA Hand was trapped No control of flow of RWC X N Daily 1 1. Lock-outs should be followed None OHS 85 0f 1993 Sec 8 & 1 8 0 8 72 72
between the safety grid rework cartons to infeed even if unlocking jams. 14
(to prevent one's hand conveyor. Unblocking a 2. Proper why-
form getting into the jam without locking out why analysis should be done for
hopper) and the rod and beforehand. No hard to access areas to prevent
his flesh were torn safe access to clean implementing solutions that might GMR Sec 5&6
build up on infeed go against FWS and Cardinal
section of hopper rules
LL004SA Employee tripped over Wearing of unsuitable LTA X N Daily 1 1. The investigation results in None OHS 85 0f 1993 Sec 8 & 5 8 0 6 78 78
GSR Sec 2 & CR Sec
an aluminium strip and apparel - the sandals reviewing general inspections 14
7(9)
fell, landing on her elbow worn could well be a being carries out regularly on the Environmental
contributing factor to her flooring and maintenance of the Regulations 6
tripping. general building. It has been
Although agreed that the problem has not
general inspections are adequately addressed to
carried out regularly on accommodate natural hazards
the flooring and such as the expansion of the
maintenance of general building during summer months
building , the problem causing the carpeting to lift, hence
has not been adequately being a contributing factor to why
addressed to the aluminium strip is lifting Facilities Regulations
accommodate natural GNR.924.9
hazards such as the CR Sec
expansion of the building 8
during summer months
causing the carpeting to
lift, hence being a
contributing factor to why
the aluminium strip is
lifting
Page 40 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL005SA Injured employee was The sealing of the LTA X N Daily 1 1. Machine improvements to None OHS 85 0f 1993 Sec 8 & 5 4 0 8 72 72
trying to align the sachet Winpak & Prodopak correct the inconsistent 14
paper when his index machine are different . performance to currently being
finger was jammed by The Winpak sealing jaws investigated. 2. The
the sealing jaws - digit do not move during the machine has not performed as per
amputation. sealing process and the our expectations since GMR Sec 5&6
Prodopak machine procurement. Poor inherent
sealing jaws will perform engineering design has resulted in
a horizontal and vertical poor production outputs and is a
motion as part of its safety risk. We therefore propose
sealing cycle. This was scrapping this equipment. GSR Sec 2 & CR Sec
not considered when the 3. 7(9)
injured employee was Installed an upgraded version of
aligning paper. Due to the current interlocks
poor engineering design 4. Poor
of this machine we have engineering design, material
been experiencing deficiency, material width and
inconsistent unsafe practice by the injured
performance which employee led to the accident
results in too much
operator intervention to
keep this equipment
LL006SA Employee was clearing running LTA X N Daily 1 Awaitng Lesson's Learnt None OHS 85 0f 1993 Sec 8 & 5 8 0 8 ### 104
jam-up on Case Packer 14
around "Jiggles and Go"
whilst it was running and
his left arm got caught
between the main shaft GMR Sec 5&6
and flight bars. His left
arm was broken
GSR Sec 2 & CR Sec

7(9)
Page 41 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL001GBL Road Traffic A Unilever Territory Fatality X N Daily exposure 1 1) Pedestrians are the most at risk in None OHS 85 0f 1993 Sec 8 & 6 4 0 8 80 80
Manager truck struck an by all staff. developing countries, especially 14
11 year old boy while children as any behaviour can be
travelling home form expected. It is the responsibility of the
visiting a client driver to manage all situations while
driving. National Road Traffic
2) Managers should ensure that: Act
A formal Behaviour Observation
system for all drivers who are
expected to drive on Unilever
business is in place CR 7(9)
Ensure that Defensive Driving
Training for all personnel is up to date
Minimum driving experience is
specified in job requirements
LL002GBL Falling from Height Fall From Height at a Fatality X A 1 1) Guest houses and other similar None OHS 85 0f 1993 Sec 8 & 4 6 0 5 50 50
Unilever Guest House operations owned by Unilever should 14
be subject to the same safety
standards as factories, this should
include risk assessment for all work
activities, contractor selection,
provision of appropriate PPE,
adequate supervision and the training
of contractors and staff.
CR 7(9)
Page 42 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL003GBL Natural Causes An employee died from Fatality X A 1 1) Risk Assessment None OHS 85 0f 1993 Sec 8 & 10 3 0 10 ### 130
natural causes (a Consider worst case scenarios in 14
cardiovascular related terms of personal risks (i.e., sudden
incident) during an off-site death from heart attack), when
workshop. considering emergency response plan
The RA must cover the off-site event
from start to finish including
unforeseen activities conducted in
own time
Physically verify critical aspects of CR 7(9)
the emergency response plan
(ambulance response time, number of
ambulances at hospital, traffic
conditions to hospital, alternative
methods of transport, level of training
of paramedic attending off-site
activity, etc,)
Check with the Occupational Health
Office who the high-risk individuals
are, and if required have a paramedic
in attendance
2) People
Leaders must emphasis that
individuals have an “opt-out” option
as early as in the joining instructions
Venue / Activity & Emergency
Preparedness
Conduct formal training (in safety at
off-site activities) for conference
organisers (internal and external)
Have hard-copy of emergency plan
on-hand (especially emergency
numbers) with automatic trauma
counselling “built” into plan
LL004GBL Road Traffic Road Traffic Fatality Fatality X N Daily exposure 1 1) Drivers should always be alert to None OHS 85 0f 1993 Sec 8 & 4 6 0 5 50 50
involving Unilever by all staff. the possibility of people walking into 14
contracted bus the path of their vehicle, in areas
where this is more likely the
possibility should be included in
driver training/assessment, awareness National Road Traffic
can be assessed during a commentary Act
drive
2) Where dangerous maintenance
practices are observed on roads,
organisations could engage with road CR 7(9)
maintenance organisations or
enforcement authorities on safety
matters
3) Drivers should ensure they are fit
to carry out their work, bus drivers in
particular are responsible for the
safety of many people
Page 43 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL005GBL Road Tank collapse in Off loading of hazardous Non-Injury X A 1 1) Establish a maintenance plan for None OHS 85 0f 1993 Sec 8 & 8 4 0 3 36 36
sulphate discharge chemicals. critical pressure equipment 14
2) Develop appropriate operational
procedures for safe discharge and
contractor/logistic operators
capability. HCS Sec
Air 3) Automatic relief valves must be 3,4,7,9,9A,10,11-16
pollution. fitted at the compressed air network
system before the truck valve.
4) A system must be in place to
define tanker specifications and check
that the contractor/logistic operator
conducts inspections of the Relief
valve, including all hydrostatic tests
for the Road Tank and related
protection devices.
5) To ensure controls are adequate,
visible and cannot be misused. (e.g
limit control operation to maximum
design pressure)
LL007GBL Road Traffic Accident Other drivers driving Fatality X N Daily exposure 1 1) Seat belts must be worn at all None OHS 85 0f 1993 Sec 8 & 4 6 0 8 80 80
under the influence of by all staff. times-they saved Unilever driver’s 14
alcohol. life.
2) Once you observe suspect/unsafe
behaviour on the road take adequate
corrective action in good time. National Road Traffic
3) All safe travel guidelines and rules Act
need to be consolidated and
simplified into an easy to access and
understand document.
4) Vehicle usage policies must be CR 7(9)
reinforced regularly.
LL008GBL Failure of Reinforced Inspection and Fatality X N 1 1) Any new boiler installations should None OHS 85 0f 1993 Sec 8 & 8 7 0 5 75 75
Concrete (RCC) Cover of maintenance of boiler incorporate blowdown vessels and not 14
Boiler Blow down pit blowdown pits. blowdown pits.
2) A survey should be conducted to
list all pits in manufacturing sites
covered by RCC slabs. All pits should VUPR Sec 1 - 4,6 -
be on a regular inspection plan, the 9,13,-16-20
undersides of the slabs (concrete and
MS) to be inspected particularly
where the are exposed to water and
other chemicals.
3) The design of blowdown pit covers
should be checked by experts in the
field.
4) All blow down pits should
incorporate a vent pipe to help reduce
corrosion.
E 5) Minimise /Eliminate the need to
walk on such covers where feasible
and if for operational reasons it is
required then provide independently
supported walkways.
Page 44 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL009GBL Road Traffic Other drivers driving Fatality X N Daily exposure 1 1) Defensive driving training courses None OHS 85 0f 1993 Sec 8 & 4 6 0 8 80 80
recklessly. by all staff. should be reviewed to ensure that 14
adequate focus is placed on the
identification and avoidance of unsafe
situations.
2) Drivers behaviors on the road National Road Traffic
should be monitored closely. Act
3) Leadership must continue to focus
on Value Life Value Safety
promotional activities with more
emphasis on Defensive Driving Tips CR 7(9)
in addition to the basic 10 golden
rules.( The new theme to introduce as
a result of the last accident is: “It
doesn't have to be your fault to get
killed in a car accident.” )
LL010GBL Operating machine Failing o comply with the Fatality X N Daily exposure 1 1) Power isolation should not be None OHS 85 0f 1993 Sec 8 & 6 9 0 8 ### 120
lock-out procedure and by all staff. relied upon unless made fool-proof 14
working on electrically through a robust lock and tag system,
live machinery. these can be used in tandem with an
inching control button that requires
the operator to hold the button down GMR Sec 5&6
to maintain rotation, in a position that
makes it impossible for one person to
rotate the blades within reach of the
vessel.
2) High hazard tasks should be
identified and PTW implemented for
these (e.g., vessel entry, cutter entry
etc)
3) There must be sufficient and
suitably trained managers, engineers
and operators to safely cope with
volumes. Operating double shifts is
not sustainable.
4) Foreign matter (especially nylon
fibre) must be prevented from
entering the process.
LL011GBL Driving Failing to comply with LTA (Permanent X N Daily exposure 1 1) Speed limits and all traffic None OHS 85 0f 1993 Sec 8 & 4 6 0 8 80 80
National road traffic act Paralysis) by all staff. signalization shall be respected at all 14
by not wearing a times.
seatbelt. 2) Safety devices in vehicles are
installed to protect and save lives,
thus they have to be used according to National Road Traffic
manufacturer ´s recommendations. Act
3) Vehicle Safe Driving standard is
designed and will be attended for all
those Unilever employees driving a
company car and /or travelling for CR 7(9)
business purposes.
Page 45 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL012GBL Road Accident Failure to observe traffic Fatality X N Daily exposure 1 1) A third seatbelt is required for all None OHS 85 0f 1993 Sec 8 & 4 6 0 8 80 80
conditions ahead. by all staff. third-party trucks travelling with three 14
(3) passengers.
2) There is a need for sustainable
program to ensure compliance of
Failure to third-party to SHE standards. National Road Traffic
follow safe travelling Specifically the 10 basic behaviors for Act
distance. Road Safety.
3) Ensure compliance of third-party
trucker to local
legislations/regulations of wearing CR 7(9)
seatbelt.
LL013GBL Crash involving Unilever Failure to operate Fatality X N Daily exposure 1 1) Whilst a formal contract existed None OHS 85 0f 1993 Sec 8 & 5 6 0 8 88 88
Vehicle vehicle at a safe speed. by all staff. between Unilever and the KD, this 14
contract did not cover the use of
Unilever vehicles or SHE
requirements - contracts should cover
these areas National Road Traffic
Failure to identify 2) There should be mechanisms in Act
hazards ahead. place to ensure that the KD are
implementing appropriate safety
systems
3) KD need to CR 7(9)
be supported in developing safety and
Unauthorised use of defensive driving training
vehicle. programmes
Page 46 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL014GBL Tanker failure and Sox Failure to identify & Environmental X A Daily exposure 1 1) The composition of the material None OHS 85 0f 1993 Sec 8 & 9 5 0 4 56 56
emmisions due to acid communicate hazards. Incident by all staff. in the bund should be tested before its 14
corrosion Many deliveries removal and the results
on site. communicated to the cleaning
company when the order to pump out
the bund is placed so that the correct HCS Sec
Offloading of Hazardous disposal can take place 3,4,7,9,9A,10,11-16
Chemicals.
2) A stainless steel tanker
should always be used for acid
effluent operations unless it can be
shown through analysis there is no
acid in the effluent
3) Pumps for hazardous

materials should be routinely
maintained to prevent leakage
4)
Internal audit procedures for all sub
contractors need to be reviewed and
where necessary strengthened
5) The
site's emergency plan to keep the
people in the offices in the event of a
hazardous gas from neighbouring
industrial sites proved useful on this
occasions, The possibility of acid
vapour clouds need to be included as
a scenario for sites handling strong
acids
6) Emergency Procedure 12.6
Page 47 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL015GBL Forklift & Forager Incorrect use of a forklift. Damage to N Daily exposure 1 1) Warehouse re assessed using the None OHS 85 0f 1993 Sec 8 & 4 6 0 8 80 80
Collision property. by all staff. HSG 136 Workplace Transport Safety 14
Guidance and actions put in place to
ensure any gaps addressed
2) Signage implemented in line with National Road Traffic

the general road signs as best practice Act
3) Team
from the warehouse operation (incl CR 7(9)
driver, shift manager, safety rep) re
wrote risk assessments from frist
principles 4) Training for warehouse
personnel revisisted and refreshed
supported by positive disciplinary
approach endorsed by shop floor 5)
CCTV deployed to improve
supervision of area 6) Behavioural
safety briefings specific to the hazards
of FLT operations implemented 7)
Independant review of area carried
out by National SHE co-ordinator 8)
Shift pattern reviewed using HSE
guidance modelling spreadsheet to
confirm not a cause. Will be included
in all future reviews. 9) Warehouse
floor to be painted at Christmas
Shutdown (2007) to fall in line with
public road markings matching best
practice
Page 48 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL016GBL Steam Explosion from a Inadequate engineering Serious incident. X E Rare exposure 1 1) Manifolds and steam headers None OHS 85 0f 1993 Sec 8 9 7 0 8 ### 128
manifold due to failure of of a pressure vessel. only during should be regarded as pressure vessels
a welded metal plate major projects. and as such their design and
fabrication should always be
recognised national or international
standards 2) Such vessels should VUPR Sec 1 - 4,6 - 9,13,-
Inadequate inspection of always be fabricated by reputable 16-20
pressure vessels. manufacturer's to a known standard
and using an Approved
Manufacturing and Quality Plan.
MHIR Sec 5
3) The quality of the vessel

with respect to vunerable areas such
as welds should be checked and its
suitability for service verified before
the vessel is put into operation
4) These
vessels should always form part of the
routine pressure vessel inspections
and ultrasonic or other appropriate
inspection techniques should be used
to examine the vessels in accordance
with national or Unilever standards,
whichever are more stringent.
LL017GBL Pulley Shaft failure Use of old equipment in Minor Injury X N Rarely 1 1) There should be regular checks on None OHS 85 0f 1993 Sec 8 & 6 9 0 8 ### 120
the processes material integrity and avoid using any 14
equipment beyond their permissible
life. Aging in metals can induce
cracks, rust formation and general
loss of thickness reducing their GMR Sec 5&6
capacity to stand loads and shear.
2) The new lifts have various accident
prevention features which are missing
in this installation
Page 49 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL018GBL Motor Vehicle Accident Failure to operate Near Fatal X N Daily exposure 1 1) Identify potential risks and train None OHS 85 0f 1993 Sec 8 & 4 6 0 8 80 80
vehicle at a safe speed. by all staff. employee to increase their capacity 14
when meet an emergency.
2) Each employee must comply with
safety driving standard strictly, e.g.
wear safety belt. National Road Traffic
Failure to identify 3) Management should ensure that Act
hazards ahead. defensive driving training
(incl.practical application) for all
drivers.
CR 7(9)
Unauthorised use of
vehicle.
LL019GBL Ammonia Escape Poor maintenance on Incident X X E Daily exposure 1 1) Ensure adequate procedures & None OHS 85 0f 1993 Sec 8 8 5 0 8 ### 104
equipment. by all staff. work instructions are in place for
operation of a votator, in particular
for restarting after any (unexpected)
stop (e.g. remove liquid ammonia
from the cylinder, melt/remove VUPR Sec 1 - 4,6 - 9,13,-
crystallised (frozen) product before 16-20
restarting). No trial & error: Never
test if the rotor is frozen up by
switching on the rotor drive motor!
2) Ensure operators are adequately MHIR Sec 5
trained on votator operation,
including ammonia refrigeration
safety basics (and periodic refreshing
training).
Consider automatic votator controls, HCS Sec
including automatic evacuation of 3,4,7,9,9A,10,11-16
ammonia from the cylinder when
product flow stops, and sequential
starting of the rotor drive motor only
when there is a product flow (lag time
after starting pump). Note 1: An
electric overload protector often acts
too slow to prevent rotor damage.
Note 2: Automatic votator controls
never replace competent operators!
3) Ensure adequate procedures are in
place for adjusting settings of safety
devices.
4) Ensure planned/preventive
maintenance plans are in place for
safety critical equipment &
components (e.g. ammonia flanges &
seals, safety devices).
5. Emergency Procedure 12.6
Page 50 of 75
Risk Quantification
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Secondary Risks
Condition N\A\E
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Rate 2011
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Health
Safety
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xF
LL021GBL Fallen platform No planning by the Injury X N Rare exposure 1 1. Always before dismounting or 7 8 0 7 ### 105
demolition team. only during working on an equipment, first try to
major projects. understand the working principle and
which are the
risks of the potential activities.
2. All devices which are hanging
Inexperience on the should first be locked and then
team. dismounted
3. Always someone should coordinate
and survey the operation
4. Immediate actions:
•Training about fundamental
knowledge of mechanics for
contractors
• Secure maintenance trainings will be
reinforce for contractors and Unilever
people
• Change the system regarding the
contractors’ monitoring
•Training of DuPont /Deep
compliance Audit for contractors
leaders
LL022GBL Battery explosion in a Accumulation of Incident X E Daily exposure 1 1. The water level of the battery OHS 85 0f 1993 Sec 8 & 5 6 0 4 44 44
Powered Hand Pallet Hydrogen during the by all EF&P and should be checked and topped up if 14
Truck Lessons charging phase. Stores staff. necessary before connecting to the
battery charger.
2.
Always charge batteries with the DMR Sec 18
Age of the battery was covers open to allow hydrogen to
not taken into dissipate. 3.Leave the battery to stand
consideration. for a while after switching off the
battery charger before disconnecting.
4.Check
level of water after charging and refill
Battery condition was if it is necessary. 5. Battery charging
not regularly checked. areas should be adequately ventilated
to eliminate high concentrations of
hydrogen. 6. Batteries used in
Forklifts must be subject to a routine
preventative maintenance
programme.Marzo 2007
Page 51 of 75
Risk Quantification
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Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
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Health
Safety
S+
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L+
xF
LL023GBL Unauthorised hazardous Driver did not follow site Incident X X E Daily exposure 1 1. Information about what to do if a None OHS 85 0f 1993 Sec 8 & 4 6 0 8 80 80
materials brought onto site procedure. by all staff. serious incident happens is given to 14
by a delivery driver every driver (this information is
available in different languages); the
driver should have seen/read this
The information when signing the HCS Sec
pesticide containers document given to him on his arrival 3,4,7,9,9A,10,11-16
were damage by the on site.
delivery companies FLT. 2. All
suppliers of raw materials will be
informed asap, reminding them that
their drivers must follow the site’s
safety rules the event of an serious
incident and not to contact the
emergency services themselves.
LL024GBL Part of the first phalange Temporal operator Injury X N Daily exposure 1 1. Place an alert where accident None OHS 85 0f 1993 Sec 8 & 6 9 0 8 ### 120
of the Operator's middle removing cups from by all production occurred–done• Re-enforce 14
finger was Cut off moving machinery. & engineering communication of the SU Golden
staff. Rules–respect the safety procedure for
your role (do not intervene with
moving parts) –initiated. GMR Sec 5&6
2. Work
with Manpower/ Addecco ensure
safety training is thorough, especially
if the individuals have limited
production experience
3. Instruct
Manpower and Addecco be more
selective about individual’s selected
and previous production experience.
4. Develop the behaviour

with Line Pilots to alert the
Production Supervisor of operators
who do not work safely and ensure
production supervisors are prepared to
replace the individual.-
LL025GBL Safety switch on the first Overriding of safety Injury X N Daily exposure 1 1. Check operation/condition of safety OHS 85 0f 1993 Sec 8 & 7 9 0 8 ### 128
door broken or equipment. by all production switches on all lines on a regular – 14
deliberately by-passed & engineering weekly –basis •Create a golden rule
staff. that the unauthorised removal /
defeating of safety interlock devices
is forbidden. GMR Sec 5&6
2. Such acts should result in serious

disciplinary action.
Page 52 of 75
Risk Quantification
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Secondary Risks
Condition N\A\E
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Safety
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xF
LL026GBL Truck crashed into pipe Not following standard Incident X A 1 1. Write new procedure for waste None OHS 85 0f 1993 Sec 8 & 6 8 0 6 84 84
bridge operating procedures of container handling. 2. Reinforce 14
the waste truck. training to the contractor drivers.3.
Apply warning sign on container to
clearly identify the correct hook to
use. National Road Traffic
Act
LL027GBL Fatality at Sales Failure to heed Fatality X A Regular 1 1) Risk assessments conducted for None OHS 85 0f 1993 Sec 8 & 6 6 0 4 48 48
Convention instruction which are set exposure by all Off-Site events should consider free 14
out for the safety of staff. time activities such as swimming,
employees. sports etc.
2) Continue reinforcing the
application of the Unilever Off-Site CR Sec 7(9)
events guidance ensuring full
deployment through proper
communications network.
LL029GBL Fingers burnt by hotmelt Use of inadequete tools. LTA X N Daily exposure 1 1) Always wear PPE as None OHS 85 0f 1993 Sec 8 & 14 4 6 0 8 80 80
glue by all staff in the prescribed
palletizing area. 2) Never rush to solve a
production or maintenance
incident. Relentlessly convey the
Failure to "Stop, think and go" message to
follow basic safety rules. all in the factory
3) Task Hazard Analysis must
ensure appropriate tools for the
task are identified and provided.
Focus on details.
Failure to use provided 4) Ensure all users are trained
PPE. and aware of safety and work
instructions with Nordson hot melt
generators and all systems
handling hot products
Page 53 of 75
Risk Quantification
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Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL031GBL Ammonia Escape Failure to maintain LTA X E Daily exposure 1 1) Experienced and trained emergency OHS 85 0f 1993 Sec 8 8 5 0 8 ### 104
Ammonia containing by all staff. operatives can still make
equipment. mistakes. It is important that the
possibility of human error be
minimised.
2) For all activities with the risk of VUPR Sec 1 - 4,6 - 9,13,-
escape of ammonia, the risks 16-20
must be evaluated by the
Competent Person, and a detailed
Permit to Work must be issued;
for the standard routine elements, MHIR Sec 5
reference can be made to pre-
agreed work procedures.
3) You can never carry out too
much on the job refresher training.
4) Equipment supplied for safety, HCS Sec
such as radio phones, must be 3,4,7,9,9A,10,11-16
checked regularly that they
actually work in all areas.
5) Operatives carrying out break
ins into ammonia lines must wear
full protective masks during the
actual break in as a precaution,
whenever practical.
LL032GBL Burnt by Caustic Sosa Tasks being performed LTA X N Daily exposure 1 1) Works equipment need a None OHS 85 0f 1993 Sec 8 & 4 6 0 5 50 50
with out SOP's. by all staff. proper preventative maintendance 14
to ensure that they are always in
perfect condition.
2) Modify
Over immediately equipment that HCS Sec
confidence in tasks. caused the accident. 3,4,7,9,9A,10,11-16
3) Provide staff in the area with

protective clothing
4) Find
alternative system to transfer
chemicals between containers (for
example, direct download from
tanker)
5) Awareness
LL033GBL Road Accident Sales Other drivers driving LTA X N Daily exposure 1 None OHS 85 0f 1993 Sec 8 & 4 6 0 7 70 70
campaign (TPM lesson, monitors
Rep recklessly. by all staff. 14
and signals) about use of
eyewash in places of danger
Page 54 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
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Health
Safety
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L+
xF
LL035GBL Fall of pallets Incorrect use of a forklift. Non-Injury X N Daily exposure 1 1. To ask for technical inform to None OHS 85 0f 1993 Sec 8 & 5 6 0 5 55 55
by all the drive-in shelves supplier. 14
warehouse
staff. 2. To extend the elements on
which the pallet is located (=
Incorrect slides). GSR Sec 8
storrage & little
LL036GBL Road Collision movement area. traffic Fatalities
Failure to observe X N Daily exposure 1 1. Overconfident & risk-taking None OHS 85 0f 1993 Sec 8 & 4 6 0 9 90 90
conditions ahead. by all staff. 3.To
drivers adaptclose
require the fork lift truck.
monitoring 14
additional supervision and
training.
4.To retrain staff.
2.
Failure to Familiarity of new hires to National Road Traffic
follow safe traveling assigned area or location must be Act
distance. ensured thru an orientation on
possible risk / hazards of routes
and the covered area itself. Site
managers to travel with the new CR 7(9)
hires during the familiarization
program and thereafter at a
prescribed frequency
3. Minimize the frequency of long

travel to reduce the risk of
exposure. Improve ways of
working thru virtual sites.
4.
Having effective communication
will minimize frequency of travels.
LL037GBL Electrical Short Circuit Working on electrical live LTA & Fire X N Daily exposure 1 1)All electrical work on Unilever None OHS 85 0f 1993 Sec 8 7 6 0 8 ### 104
components. by all electrical premises, whether by Contractors
staff. or Unilever staff must
5. Air travel beiscarried
if there an
out strictly in accordance with
option.
Unilever Standards for Electrical
No contractor Safety. EIR Sec 2,3
supervission. 2) This type of 6. work could have
Insufficient sleep
beenrest
and scheduled
breaks willfor a weekend
reduce a or
a time when
drivers abilitythe line could
to react to have
been shut down
hazardous without disrupting
situations.
production. 7. EMR Sec 1,2,6,13
3) The key
Fatigue learningshould
avoidance from this
form
accident
part is that
of driver people will
training.
sometimes bypass well known
safety rules, albeit with good
intentions, and that we should be SANS 0142
more aware of this human
behaviour and be more proactive
in discouraging it. This behaviour
cannot be prevented by just
publishing rules alone.
Page 55 of 75
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Secondary Risks
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Safety
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xF
LL038GBL Fire from welding task Failure to disclose all the Non-Injury X N Daily exposure 1 1. The timely implementation of None OHS 85 0f 1993 Sec 8 & 8 6 0 8 ### 112
hazards involved in the contractors. the site’s fire emergency plan 14
task. resulted in the fire being brought
quickly under control and all the
people being evacuated from the
No building in less than a minute. GSR Sec 5&7
contractor supervision. 2. All contractor activities should
be pre-discussed with the
contractor’s Unilever contact
manager and need for any special
precautions e.g. hot work permits,
working at height permits etc
identified well in advance.
3. Contractor work must be
monitored by Unilever staff to
ensure compliance with the
agreed precautions. We must not
leave the safety of our people and
assets to the unsupervised work
of contractors – even those who
have worked on the site for many
years.
4. The special risk regarding the
presence of the flammable
insulation material under the
roofing plates was not identified.
The consideration of flammable
materials hidden behind panels
etc., needs to include the site’s
Hot Work PTW procedure /
training.
Page 56 of 75
Risk Quantification
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Secondary Risks
Condition N\A\E
Risk / Impact
Environment
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Health
Safety
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xF
LL001GBL Unilever employee bus Lack of hazard Fatality Class B X N Daily exposure ±60 1. Reinforce the tenets of None OHS 85 0f 1993 Sec 8 & 6 3 0 8 72 72
accident perception in the driver. by staff. Defensive Driving with specific 14
reference to Speed in high traffic
Inadequate adherence environments and Breaking
to defensive driving distance.
principles with 2. identify High Risk Drivers in National Road Traffic
inadequate breaking order to provide meaningful Act
distance. interventions to correct driving
High speed behaviour by conducting FDRI
in traffic and not keeping Assessments.
avenues for escape. 3. Consider the use of speed CR 7(9)
limiters and black boxes in buses
to monitor Driver behaviour on the
road for the high risk drivers
4. In high risk environments,
conduct Behaviour Observations
for Drivers and discuss their
Performance with them on a
regular basis
LL002GBL Short circuit of forklift Failure to forklift battery Fire X N Daily 1 1. All forklift battery cables to be None OHS 85 0f 1993 Sec 8 & 3 8 0 8 88 88
battery cabling after safe replaced and not joined with 14
charging insulation tape
DMR Sec 18
LL003GBL Fall from top of tanker Driver did not follow Fatality Class B X N Daily 1 1. Review site procedures and None OHS 85 0f 1993 Sec 8 7 8 0 8 ### 120
site’s procedure / work PPE requirements for each task
instruction to use the with Third Parties.
provided fall protection. 2. Control the movements and
Driver did not identify the activities of third parties while on
hazard of working on the site. GSR Sec 6,13
top of the tank and in an 3. Review signage on site to
attempt to save time or ensure adequate communication
effort failed to used the of procedures.
required fall protection 4. Review and conduct risk
equipment. assessments for all high risk CR Sec 8
activities including tank truck and
rail car loading and unloading.
5. Consider the use of a “buddy”
system for working at height tasks
which require fall protection.
Page 57 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL004GBL Wrist injury Improper attempt to save Injury X N Daily 1 1. Promote hazard identification, None OHS 85 0f 1993 Sec 8 3 8 0 8 88 88
time and routine. risk assessment and change
Inadequate or management tools to control
improper controls - lack safety of operations;
of controls to mitigate 2. Rules and practices which are
the risk of moving parts in place to guard health and GMR Sec 1-4,7
of the equipment. safety must be enforced at all
Inadequate times, reinforce the benefits of
assessment of risks - and apply behavioural audits.
excepting electrical
safety risks were not (re) 3. Consistent and intentional rule DMR Sec 2&11
evaluated assuming the breaking must be subject to
transfer of an disciplinary action.
operational equipment
LL005GBL Electrical Shock Inattention to hazards. LTA X N Monthly 1 1.Contract Company to conduct a None OHS 85 0f 1993 Sec 8 5 8 0 4 52 52
Not recognising complete review of their Safe
the fact that working on Systems Of Work and submit to
live equipment could Unilever for approval.
result in injury. Contract Company need to ensure
Improper work that all of their Operatives EIR Sec 2,3
habits i.e risk understand Regulation 14 of The
assessment implies that Electricity at Work Regulations
they can work on live 1989 re Work on or near Live
equipment Conductors. 2. In particular the
Contract Company should have EMR Sec 1,2,6,13
clear rules or method statements
for isolation and for work on or
near live electrical parts, including
precautions to be taken.
3. Report to be circulated to SANS 0142
Company contacts and arrange a
review meeting with ALL site
company contacts relating to Risk
Assessments & Method
Statements.
LL006GBL Fire in Electrical Room Failure of Electrical Fire X N 1 1. The main cause for the None OHS 85 0f 1993 Sec 8 5 4 0 1 9 9
equipment downtime was not the direct
damage by the fire, but the toxic,
corrosive smoke !!!
2. Electrical components do fail,
be prepared when it happens. EIR Sec 2,3
3. Keeping all cabinet doors
closed limits the spread of smoke
damage in the event of fire.
4. Separate burned areas from
production areas as soon as EMR Sec 1,2,6,13
possible with plastic sheets,
because the smoke/smell
emission remains for days and
contaminates further product and
equipment. SANS 0142
Page 58 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL007GBL Tea Loader trapped by Lack of warning system Fatality Class A X N 1 1. Task hazard analysis need to None OHS 85 0f 1993 Sec 8 & 7 5 0 8 96 96
gate of Mechanical Tea in closing / opening of be conducted for all operations 14
Harvesting Machine the rear hydraulic with a man machine interface
operated door/gate. 2. All control switches should be
Door closing switch located in the line of sight close to
located in the cabin particular operation. GMR Sec 5&6
rather than at the rear of 3. Warning systems should be in
machine. place based on task based risk
Inadequate risk assessments for equipment
assessment - failure to operated remotely without line of
identify the hazard and sight (e.g. reversing vehicles,
consequential risk. gate closures etc.)
Inadequate 4. Scanning of blind spots while
scanning/scrutiny of the operating equipment to be
offloading area - should incorporated as part of SOP’s.
have boarded after
ensuring door was safely
closed
LL008GBL 3rd Party driver injured Ignoring basic safety LTA X N 2 1. To review and improve the None OHS 85 0f 1993 Sec 8 & 5 8 0 8 ### 104
whilst loading paper and rules for loading instruction procedure for third – 14
cardboard into a truck operations. party employees present on site
using a forklift Not ensuring that there 2. To agree with the 3rd party
are people in the way organizations the system of
during loading process instructing their employees before DMR Sec 18
near the working area coming to the site
3. To apply more strict control for
the 3rd party working at site from
the responsible person
4. To review safety procedures
Page 59 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL009GBL Unilever van accident Poor risk perception by Fatality Class B X N 1 1. All employees must receive None OHS 85 0f 1993 Sec 8 & 7 8 0 8 ### 120
Driver due to which he Defensive Driving training when 14
was driving at a speed they join work and are required to
higher than warranted by drive on Unilever business.
traffic conditions. 2. Special care needs to be taken
The for young male drivers who are National Road Traffic
Young newly hired driver overconfident and risk takers. Act
did not receive They should receive more
Defensive Driving frequent refreshers in Defensive
Training before getting Driving – Once in two years as
charge of the vehicle. against once in three years for CR 7(9)
others
Poor road conditions 3. Minimize long trips to reduce
as edges of road are the risk of fatigue. If no alternative,
rough where the cyclists driver rest breaks at least every 2
can lose balance. hours should be enforced.
Despite rest
brakes, the driver would
have been tired after 8.5
LL001GBL Open cut-outs on the Open cut-outs
275kmon of the Serious incident. X N 1 1. Cut-outs to be covered as soon None OHS 85 0f 1993 Sec 8 & 5 3 0 1 8
Not Rated in 2010

hrs and
false ceiling false ceiling
travelling as they are made. No opening is 14
too small. Tools can definitely fall
No designated walking thro’ smaller opening and in worst
marking / cut out case situations as in this case,
indication on false ceiling people can fall through.
CR 7(9)
2.
Although work was being carried
out on walk-on false ceiling, safety
belt anchoring to life line at all
times is a must due to openings
provided on the false ceiling.
3. As there are many

obstructions such as ducts, cable
trays, light fixtures,
Page 60 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL002GBL Unilever Canun Mexico. Lack of Situational Serious Injuries X N 54 1. Coordination of large events None OHS 85 0f 1993 Sec 8 & 5 3 0 3 24
Fifty-four people from Awareness: Staff requires good management and 14
Field Sales Force were climbed on to a structure the selection of good competent
injured when a 3-m high that was obviously contractors
metallic structure poorly made with out 2. The use of temporary stands
(scaffold) collapsed as considering their own (scaffold) for photography CR Sec 7(9)
the team was preparing health or thinking that sessions is forbidden in Mexico.
to take a group the stand could collapse. In the region the use of temporary
photograph Inadequate Contractor stands for taking large group
Selection: The photographs (and the need for
photographer and his taking these photographs) will be
subcontractor for the reassessed.
stand erection were not 3. Where timetables and
able to identify the arrangements are changed
needs for a stand to hold appropriate communications must
a large number of be put in place to ensure risk
people. assessments are still valid and
Inadequate Inspection: hazards are
The re-constructed stand adequately controlled.
was not assessed for 4. Training of staff in hazard
suitability by a awareness and their responsibility
competent person in for their own safety should be
adequate lighting. reinforced.
Inadequate Evaluation 5. However unlikely consideration
of Exposures and should be given to the possible
Needs: The taking of events that could occur and
large group photographs suitable emergency arrangements
where employees are must be put in place.
placed at height on
temporary structures
was not assessed for
second
photography session.
Also the need for
emergency plans when
large groups are
assembled was not
Page 61 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL003GBL Russia 1. Lack of Situational Fatality Class A X N 1. Unilever Contact Managers for OHS 85 0f 1993 Sec 8 & 7 8 0 6 90
Awareness: Although such Greenfield projects must 14
training was given at the ensure that proper work method
beginning of the job the statements are made and
failure to close the safety enforced for all hazardous tasks
door indicates that the as per Unilever’s Safe CR Sec 7(9)
knowledge of the risks of Management of Contractor
working at height and Standard. Such tasks would
the importance of safety include Working at heights, heavy
harnesses was not lifting of materials of construction,
understood. Vessel Entry, Excavations etc.
2. Inadequate
Leadership or 2. Rigorous
Supervision: Failure to supervision by a competent
supervise subcontractors person of
and ensure PPE was subcontractors/contractors while
attached and safety working at height must be in
devices (guard doors) place. Ensuring identified risk
were closed reduction measures are in place
3. Inadequate and effective including: Fall
Identification of loss protection harnesses worn at all
exposures: The permit times and that harnesses are
to work procedure did attached to suitable anchor points
not adequately identify Unilever’s Safe Management of
the need for alternative Contractor Standard. Such tasks
lifting equipment would include Working at heights,
4. Inadequate Control heavy lifting of materials of
of Construction: construction, Vessel Entry,
Submission of Work Excavations etc.
Method statements for 3.
Hazardous tasks to Safety Awareness training for
Unilever Project contractors/ subcontractors and
Manager by the employees working at heights
contractor was not must be reinforced.
enforced thus leading to
a lack of role clarity
4. Hand and Power Tools
Page 62 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL004GBL Brazil Lack of skill: Contractor Serious Incident - X N 1 1. The procedure of equipment None OHS 85 0f 1993 Sec 8 & 8 8 0 5 80
electrician was in a new Amputation raising was totally revised and the 14
function and he was not contractors
properly trained do to were
the task. trained including isolating the work
Inadequate area CR Sec 7(9)
Orientation: The
training program for 2. New
employees in new roles contractors or contractors in a
and / or for new new jobs must be required to
employees is not prove their competence to carry
sufficient or effective out the tasks required.
Inadequate initial
instruction: The 3. To be
contractor was no clear on all activities contracted
sufficiently trained to with a third party contractor with
carry out the task, clear roles and responsibilities.
specifically the
requirements for no lone
working, the need to
isolate the work area
and proper use of the
sling to lift the equipment 4.
Lack of Situational Written method statements and
Awareness: Contractor risk assessments to be provided
“2” passed through routine maintenance tasks. Non
where he shouldn't’, routine tasks to be controlled by
however, the work area permit to work procedures.
was not isolated.
Inadequate Work
Standards: It is not
entirely clear the
responsibility for training
this type of contractor
LL005GBL Malaysia Unsafe act by the three Fatality - Class B X X 1 1. Develop standard safety cage None OHS 85 0f 1993 Sec 8 & 7 4 0 5 55
Not Rated in 2010

victims as well as the design and mandate SOP. 14
reach truck driver
Inadequate SOP and 2. Frequent periodic audits of
training of driver and warehousing operations by
workmen Service Provider and Unilever CR Sec 7(9)
Inadequate control and Personnel.
supervision as the
unsafe act continued
without control by 3. Hazard Analysis of
supervisor all operations related to use
Inadequate audits and forklifts, Reach trucks, safety cage
checks by IDS staff etc.
Inadequate cage design
and operational
safeguards
Page 63 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL006GBL Burton, UK The hazard was not X N 1. Contractor control: briefing , None 2 8 0 6 60
seen due to low light management
levels in outside storage
area at 06:00 2. Reporting of all
The material which incidents, accidents , near misses
caused accident was left etc. in a timely manner
there by a contactor, 3. Re-
which was not the area evaluation of night time outside
designated to them. working, in particular lighting Lux
These materials had levels 4.
been cause of a Poor control of storage in the area
previous incident, (which where the accident occurred
caused the wire mesh to
be damaged – see
picture), but
this was not reported
immediately and the
situation had not been
made safe.
The hazard was not
seen due to low light
levels in outside storage
area at 06:00
The material which
caused accident was left
there by a contactor,
which was not the area
designated to them.
These materials had
been cause of a
previous incident, (which
caused the wire mesh to
be damaged – see
picture), but
this was not reported
immediately and the
situation had not been
Page 64 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Risk I.D.
Health
Safety
S+
P+
L+
xF
LL007GBL Europe The operator did not LTA X N 1. Re-enforce the golden rules 5 5 0 6 60
visually inspect all the especially the one concerning the
machine before starting wearing of the adequate PPE's.
the cleaning operation To follow the golden rules is
There had be no break mandatory and no excuse can
of jars during her shift, justify any deviation.
so she did not identify 2. The fact that two
the risk of the presence cleaning tasks were following
of glass each other, one with gloves and
She didn’t make any the other without gloves, must be
difference between her identified in the risk assessment of
previous task without the workplace, and described in
gloves and the next the safety instruction.
cleaning task for which
gloves were needed.
She didn’t think about 3. Re-start the TPM
the potential risk for this inspection standards after and
new task. before cleaning.
She didn’t want to loose 4. Always take time
time between the two to think about safety before
tasks – the rule is to starting any activity by questioning
wear gloves for cut ourselves "what could happen if"
protection and also
plastic gloves to avoid
moistening the gloves for
cut protection
The operator is
energetic – she wants to
LL008GBL Norwich do
Lackwell
of and fast
understanding of Minor Incident X N 1. A robust risk assessment 3 8 0 6 66
Not Rated in 2010

how the plant might process is required to identify
possibly operate under hazards present under fault /
fault or abnormal abnormal conditions, and to
conditions. understand the manifestation of a
Investigations suggests hazard and put in place
that the full isolation and appropriate controls - Basic/Root
drain down procedure Causes.
has been followed,
however there was still
water present in the 2. Faults with
system to interact with equipment should be recorded
the steam and cause a and rectified immediately.
release of steam and hot
water.
3. The Operator stated in the

investigation that a water supply
shut off valve was difficult to fully
close, and had been for a number
of months. All Operators in the
area must be aware of the
location of emergency showers. A
shower was in the room the
Operator was scalded in, but he
was moved to another room to be
treated with cold water. Quick
reaction is key to minimising the
damage caused by burns
Page 65 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Risk I.D.
Health
Safety
S+
P+
L+
xF
Arad, Israel One of the LTA X A 2 Standard Instraction , People None OHS 85 0f 1993 Sec 8 & 4 6 0 4 40
extruders(BC-92B) got working on extruder operation 14
jammed ;while syhould wear :Correct PPE to be
production was on. At warn at all times, Heat resistant
that time , the content gloves , Googles and long
inside the extruder was sleeves. GSR Sec 2,5,7
120 C. The operator was
wearing all required PPE
and the supervisor was
not wearing any PPE. At
first inserted water into HCSR SEC1-17
the extruder to get the
extruder back into
operation, after opening
the lower ring of the Dies
housing the supervisor MHIR Sec 1-10
hammered the upper
ring to complete the Die
opening process .At that
moment the hot material
sprayed out injuring the
supervisor causing him
2nd degree burns on his
hand and minor burns
on his face,the line
supervisor got injured
because He was not
wearing PPE
EXTERNAL / OTHER RISKS
ER001 Temporary Disability Miscarriage / Premature X N 8 Months / 2 UL Pregnancy @ work procedure n/a OHS 85 0f 1993 Sec 8 & 10 8 0 1 18 18
birth 1 x Year New and Expected mothers @ 14
work Guide for Employers
(ISBM0/7176/08/26/6)
Maternity Leave Risk
Assessments Medical
Surveillance MSDS Sheets
Employment Equity Act 55
Basic Conditions of
Employment Act CR 7(9)
Basic Conditions of
ER002 Temporary Disability Lost Time X N Medical Surveillance n/a OHS 85 0f 1993
Employment Act Sec
Sec 8 & 10 8 0 3 54 54
Fatality Medical Centre Medication 14
25&26
CR 7(9)
Page 66 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
ER003 Temporary Disability Lost Time X N 12 HRS/ Day Return to work procedure n/a OHS 85 0f 1993 Sec 8 & 9 0 2 8 88 88
Fatality 14
Tolerable & Saturated Risks. These risks have by means of the reasonable man been mitigated to the extend that they can not by any means be made more effective than they already
are. They will be reviewed on an annual basis unless any of the following take
SAFETY
EFP005 Moving packaging Unstable load falls off Serious injury, X N 500kg.Daily 1 Awareness, Training, SOP None OHS 85 0f 1993 Sec 8 & 3 3 0 10 60 60 (T)
ONPHS material around the floor and may cause injuries fatality or property exposure 7.5.14.8.Safe stacking practise 14
using a powered pallet if it falls to people nearby and product
truck damage.
GSR Sec 8
EFP008 Walking too close to hot Some of the heated People burning X N 2m unlagged 120 PPE, warning signs on pipes, None OHS 85 0f 1993 Sec 8 2 5 0 10 70 70 (T)
ONPHS surfaces/pipes or pipes not being lagged themselves due to pipe at + 60 induction
machinery in the or clearly identified. contact with hot degrees.Daily
Margarine Hall. surfaces - exposure
superficial burn
wounds such as Hygiene & ergonomic
blisters. Surveys
EFP009 Process plant Operates with air Damage to plant X N 10 MPU’s N/a Engineering daily inspections, well None OHS 85 0f 1993 Sec 8 2 5 0 10 70 70 (T)
ONPHS causing process equipment also experienced operators
vibration and possibility of injury.
subsequent property
damage
Hygiene & ergonomic
EFP012 Normal use, wear and Deterioration of Asphyxiation, injury X N 64 seals. Daily 20 Replace seals when small leak None OHS 85 0f 1993 Sec 8 &
Surveys 3 4 0 10 70 70 (T)
ONPHS tear / Deterioration of the ammonia seals leading or fatality. Damage exposure detected (smell) 14
Ammonia barrels inside to large leak which will to property.
the Schroder lead to anybody in the Refer to CAPEX 2009
department inhaling
ammonia and this will GSR Sec 2,5,7
lead to health effects
EFP014 Normal plant utilisation Inadequate replacement People burning X N 60 m of piping 1 Replace corroded steam piping None OHS 85 0f 1993 Sec 8 & 4 3 0 9 63 63 (T)
ONPHS of Steam lines behind P of corroded pipes could themselves due to when reported. RCM & 14
tanks lead to rupture and the contact with hot Inspections HCSR SEC1-17
burn people around the surfaces -
pipe that has ruptured superficial burn
wounds such as GSR Sec 2,5,7
blisters.
MHIR Sec 1-10
HCSR SEC1-17
MHIR Sec 1-10

Page 67 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP017 Loading Boxes down the Boxes coming down Boxes coming X N 10 chutes / 10 40 Chutes are designed with lips so None OHS 85 0f 1993 Sec 8 3 5 0 8 64 64 (T)
ONPHS chutes for packing chute travel at a speed. down chute may loads per shift that no person has to catch boxes
injure persons as they come down. Employees
hand at bottom of are not allowed to put their hands
chute if his /her inside the chute during loading
hand is left inside Hygiene & ergonomic
the chute during Surveys
loading of boxes
EFP026 Normal process Spillage of margarine in Injury, fatality or X N 12.7m2 affected 40 PPE, 5S housekeeping audits in None OHS 85 0f 1993 Sec 8 & 2 5 0 9 63 63 (T)
ONPHS the plant could lead to even paralysis. at a time. Daily Old and New Packing Hall on 14
slippery conditions and exposure weekly basis and keeping proof
employees who are not thereof. TPM AM cleaning daily.
careful when walking in Drip trays provided
the plant can walk on ERW Sec 6
spillage and slip and get
injured
EFP033 Storing of Chemicals Too much being ordered Fire or explosion. X N ± 1185 5 Flavour store locked key held by Fire can OHS 85 0f 1993 Sec 8 & 5 2 0 10 70 70 (T)
ONPHS so current store is not Injury or fatality kg.Crearasa,BK responsible persons, controlled spread to 14
adequate balance is (Asphyxiation) V 45 & 85,Lis temperature. Alarm in place. Fire adjacent
stored in Flavourant 24,Sen03, extinguishers available, sprinkler buildings
Store which can lead to ES144 system and emergency team
fire if the containers available GSR Sec 2
tipped over or leak and
thus come into contact
with different chemicals
on the floor a chemical
reaction will happen and HCSR SEC1-17
thus cause fire or
explosion.
EFP034 Chemical storage If aircon in flammable Fire or explosion. X N ± 1185 / R500 8 Alarm in place giving indication of None OHS 85 0f 1993 Sec 8 & 4 2 0 10 60 60 (T)
ONPHS store fails no warning Injury or fatality. 000.Crearasa,B temperature increase. Fire 14
bell to advise, fire could KV 45 & 85,Lis Warning system being Dangerous Goods
break out and cause 24,Sen03, implemented, . Trained Fire- storage Permit
damage to property and ES144 Fighters on shift, extinguishers
possible cause injuries available. GSR Sec 2
to employees
EFP036 Working on moving Overall (non – Serious injury or X N Artisans work 5 Lock out procedure, trained None OHS 85 0f 1993 Sec 8 & 5 3 0 8 64 64 (T)
ONPHS machinery by artisan elasticated sleeves) loss of limb. on machine personnel. No work done on 14
could get caught in during moving equipment, except HCSR SEC1-17
moving machinery. breakdowns or FAULT-FINDING. Unless declared
during fault competent.
finding. Daily GMR Sec 1,2,3,4,5,6,10
exposure
Dangerous Goods
storage Permit
EFP038 Working on moving New people in dept. Serious injury or X N 2 main 15 Induction, warning signs. None OHS 85 0f 1993 Sec 8 & 4 2 0 8 48 48 (T)
ONPHS machinery might not be aware why loss of limb. conveyors / 12 Equipment risk assessment 14
alarm is going on/off for packing lines induction done to all new
conveyors starting up, employees.
leading to injury if
employees put hands in GMR Sec 1,2,3,4,5,6,10
conveyors unaware that
it can start at anytime.
Page 68 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP039 Working on moving If proper lock-outs are Serious injury or X N As per 20 Supervision, All maintenance None OHS 85 0f 1993 Sec 8 & 6 6 0 6 72 72 (T)
ONPHS machinery not followed by the loss of limb. maintenance or people issued with correct lock out 14
person working on a project work. equipment(caliper, lock, valve and
machinery chances are Daily exposure chain) on lockout, register
big that somebody can to all lines available for all padlock owners
start the machine GMR Sec 1,2,3,4,5,6,10
unaware that there are
people working on it and
they can get injured.
EFP040 Working on moving If machinery runs Serious injury or X N Daily exposed 10 Daily walkabout supervision, Lost None OHS 85 0f 1993 Sec 8 & 5 2 0 10 70 70 (T)
ONPHS machinery without machine guards loss of limb. to 15 lines time record can identify who 14
or guards not replaced worked on line, Awareness done
after maintenance this to operators.
will lead in machinery
running with moving GMR Sec 1,2,3,4,5,6,10
parts exposed and if
people put their hands in
that exposed machines
they can get serious
injuries
EFP041 Maintenance on Goods Procedures not being Injury, fatality or X N 2 lifts / 2.5 tons 2 Appointment of competent None OHS 85 0f 1993 Sec 8 & 8 4 0 5 60 60 (T)
ONPHS lift / elevator adhered to by competent even paralysis. each contractors 14
3rd party or using lift
incorrectly.
GMR Sec 1,2,3,4,5,6,10

EFP042 Normal operation of Filling up of lift shaft with Possible X N 5m3 water. N/a Sump pump available in the lift to None OHS 85 0f 1993 Sec 8 & 2 4 0 10 60 60 (T)
ONPHS lift/elevator water from floor electrocution or Daily pump out water from the shaft. Lift 14
washings / spillages fatality. exposure .2 lifts serviced regularly according to the
causing shorting out of contract
electrics and this will
lead to lift breaking GMR Sec 1,2,3,4,5,6,10
down/jammed
EFP043 Pregnant woman walking If pregnant ladies are Could lead to X N Not easy to 1 Medical induction done. None OHS 85 0f 1993 Sec 8 7 10 0 3 51 51 (T)
ONPHS through EF&P exposed to extreme heat miscarriage quantify
conditions they can
suffer from heat stroke
because of the extra
weight and hormonal Hygiene & ergonomic
imbalance Surveys
EFP044 Operation of Ammonia Insufficient venting pipe Injury, fatality and X E 32 barrels / R26 10 Daily inspection by Aldo None OHS 85 0f 1993 Sec 8 & 4 2 0 10 60 60 (T)
ONPHS pipes in old hall for ammonia leading to exposure to 000 each Emergency Procedure 14
inadequate pressure ammonia 12.6
relief leading to (asphyxiation) ERW Sec 2
catastrophic failure of
the barrel GSR Sec 2,5,7
EFP046 Processing with Cold Hot water used to heat Burn wounds and X N 80 degree water 10 Awareness None OHS 85 0f 1993 Sec 8 & 5 3 0 8 64 64 (T)
ONPHS pipes on the lines up pipes – water could blistering. daily exposure 14
burn passers by / especially in
operator winter
HCSR SEC1-17
CR Sec 7
Page 69 of 75 MHIR Sec 1-10

GSR Sec 2
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP048 Use of Power tools and If water on floor Possible X N 220 volts>Daily 2 Registers, Inspections, and the None OHS 85 0f 1993 Sec 8 & 7 2 0 8 72 72 (T)
ONPHS extension cables electrocution can take electrocution or exposure policy of Unilever is not to have 14
place if cord has fatality. extensions with joints.
exposed wires and
employee touches it
GMR Sec 1,2,3,4,5,6,7
EFP049 Operation of Date Suspect plugs for date Possible X N 15 date coders 10 Engineering site standard. Hazard None OHS 85 0f 1993 Sec 8 & 7 2 0 8 72 72 (T)
ONPHS Coders coders not IP65, could electrocution or daily exposure spotting exercise 14
lead to electric shock fatality.
when came into contact
with EMR Sec 2,9,13
EFP054 Performing of general Incorrect lock out Electrocution, X N Daily exposed 2 Supervision, All maintenance None GSR
OHS 85Sec 2 Sec 8 &
0f 1993 5 3 0 8 64 64 (T)
ONPHS maintenance in area procedure may lead to fatality, injury or to 15 lines people issued with correct lock out 14
equipment being started loss of limb equipment(caliper, lock, valve and
up and injuring persons chain) on lockout, register
available
GSR Sec 2
EFP063 Changing swing bends If an employee X N Only opened 1 Operators trained.Spanner None OHS 85 0f 1993 Sec 8 & 4 5 0 7 63 63 (T)
ONPHS open the swing during CIP's.All provided 14
bends without lines.Water 550
closing valves he
can burnt by the
hot water GSR Sec 2,5,7
EFP064 Changing swing bends If an employee open the Chemical burn X N Only opened 1 Operators trained.Spanner None OHS 85 0f 1993 Sec 8 & 5 5 0 7 70 70 (T)
ONPHS swing bends without wounds and during CIP's.All provided 14
closing valves he can blistering. lines.Caustic
burnt by the caustic temperature 750 HCSR SEC1-17
GSR Sec 2,5,7

EFP069 Taking out Unit A1 rotor Rotor is heavy and if it Injuries to X N 200kg.Its taken 5 Only taken out during Rotor can OHS 85 0f 1993 Sec 8 & 7 8 0 4 60 60 (T)
ONPHS for repairs / maintenance is not held properly it can personnel if scrapper maintenance or repairs using get 14
slip and fall. removing it - Hand blades are worn lifting equipment damaged if it
feet & leg. out and also slips and
during planned falls whilst HCSR SEC1-17
maintenance being GSR Sec 2
and also during removed
breakdowns.In
all schroeders
CR Sec 7(9)
EFP072 Working on diverter The diverter get Employees can get X N Line 7 & 8.Daily 2 Operator trained n/a OHS 85 0f 1993 Sec 8 & 3 5 0 8 64 64 (T)
ONPHS activated whilst they are hand injuries. exposure 14
busy clearing the
blockage.
DMR Sec 18
GSR Sec 2,5,7
EFP073 Changing swing bends If valve is not closed Burn wounds and X N CIP is done 4 Operator trained None OHS 85 0f 1993 Sec 8 & 4 4 0 8 64 64 (T)
ONPHS before opening the blistering. during change 14
operator can get burnt Chemical burns. over and when
by CIP there is a need.
HCSR SEC1-17
GSR Sec 2
Page 70 of 75 CR Sec 7(9)

CR Sec 7(9)
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP074 Feeding reel on the BDR Employee can get Loss of finger or X N Changed hourly 24 SOP .Only trained operators None OHS 85 0f 1993 Sec 8 & 3 5 0 9 72 72 (T)
ONPHS machine injured if he accidentally limb. in Line 7 & 8.In changed the reels 14
put his hand under 500g changed
cutting knives every 45
minutes.
GSR Sec 2
EFP075 Clearing paper jam on If two people are doing Serious injuries or X N Daily exposure 16 Only one person must perform n/a OHS 85 0f 1993 Sec 8 & 5 5 0 9 90 90 (T)
ONPHS the BDR machine this task chances are possible to all BDR this task. Operators trained 14
high that there can be amputation. machines and
miscommunication this activity is
between the one turning only done when CR Sec 7(9)
the wheel and the one there is a paper GSR Sec 2
clearing the jammed jam
paper and the one
clearing the paper can
be cut by knives. DMR Sec 18
EFP077 Adjusting / positioning If somebody turns the Serious injuries or X N Done during 4 Done by artisans. Lockout is done n/a OHS 85 0f 1993 Sec 8 & 4 5 0 7 63 63 (T)
CR Sec 7(9)
ONPHS Break rollers hand wheel whilst possible maintenance. 14
another employee is amputation. Roller weighs
doing adjustments 5kg and there
without warning him ,the are in Line
one doing adjustments 5,7,8,14,15.Also GSR Sec 2
GMR Sec 2,3,4,5,7
can get injured if the paper is
rolling
backwards or if
its skewed
CR Sec 7(9)
EFP078 Removing unwrapped Employee can get Serious injuries or X N Daily exposure 8 Its only done by an operator alone None OHS 85 0f 1993 Sec 8 & 5 3 0 9 72 72 (T)
ONPHS bricks from the moulding injured if someone turns possible in all bricks 14
drum the wheel whilst busy amputation. machines. This
removing unwrapped is done if GMR Sec 2,3,4,5,7
brick wrapper is
jammed in GSR Sec 2
wrapping table
and also if the
electric sensor
CR Sec 7(9)
EFP082 Changing / Replacing If pulling a tape to put it Laceration to X N Tape sealer in 7 Trained operators None OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 80 (T)
ONPHS tape sealer into the buffer rollers the fingers or hand. all 7 lines, two 14
blade can cut and injure (Stitches required) times per shift
the employee for 3 mins
GMR Sec 2,3,4,5,7
EFP085 Replacing V belt on When isolation is not Serious injuries or X N During 4 Done by Artisans, lock out None OHSGSR
85 Sec 2 Sec 8 &
0f 1993 5 5 0 6 60 60 (T)
ONPHS Unitator properly done whilst possible maintenance procedure in place 14
replacing V belts done amputation. and breakdown
and one starts using the
machine, the hands can
get injured CR SecSec
GSR 7(9)2
EFP086 Working on a scrapper Sharp scrapper blades Laceration to X N During 4 Done by Artisans, None OHS 85 0f 1993 Sec 8 & 5 6 0 6 66 66 (T)
ONPHS blade - Unitator can injure an employee's fingers or hand. maintenance 14
hand if (Stitches required) and breakdown
GMR Sec7(9)
CR Sec 2,3,4,5,7
GSR Sec 2
Page 71 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP088 Cleaning spillage in the If an employee entered a Injuries to X N Continuous 4 8 Only enter through spur door Serious OHS 85 0f 1993 Sec 8 & 5 5 0 6 60 60 (T)
ONPHS robot spur in order to clear personnel robots 9 spurs. injury 14
spillage or through pallet removing it - Hand Only entered
exit the robot can feet & leg. when there is a
automatically start need
GSR Sec 2
EFP090 Robot maintenance If lock out is not done Serious injuries or X N Done when 8 Done by an artisan and following None OHS 85 0f 1993 Sec 8 & 6 7 0 5 65 65 (T)
ONPHS correctly, it can start possible there is a need a lock out procedure 14
automatically amputation. or a breakdown.
CR Sec 7(9)
EFP091 Cleaning track shuttle Shuttle car can bump on Injuries to X N 15 min daily 4 Isolate and lock machine None OHS 85 0f 1993 Sec 8 & 5 5 0 6 60 60 (T)
ONPHS car employee if on the way personnel during shift start 14 GSR Sec 2
removing it - Hand up
feet & leg.
GMR Sec 2,3,4,5,7
EFP092 Cleaning of rollers under Employee can be Burn wounds and X N When there is a 5 Operator trained None OHSGSR
85 Sec 2 Sec 8 &
0f 1993 6 5 0 6 66 66 (T)
ONPHS the glue pot burned by glue if sensor complication need 14CR Sec 7(9)
is not working through infection.
EFP093 Walking through the Employees/contractors Injury or fatality. X N Daily exposure 40 Demarcated areas , signages None OHS 85 0f 1993 Sec 8 & 7 3 0 8 80 80 (T)
ONPHS palletising area can be injured by the mainly during displayed at the entrance, 14CR SecSec
GSR 7(9)2
forklift moving within the the day Induction, safety talks GMR Sec 2,3,4,5,7
area
EFP094 Operating packing If operators override Serious injury or X N Daily exposure 50 Operators trained. Awareness n/a OHSGSR
85 Sec 2 Sec 8 &
0f 1993 5 4 0 8 72 72 (T)
ONPHS machines in EF&P and safety switch/devises fatality. to all machines done 14
GMR Sec7(9)
CR Sec 2,3,4,5,7
Bottling he/she can put
employees lifes in
danger if anything goes
wrong in the machine CR SecSec
GSR 7(9)2
EFP095 Cleaning swelling on the If any employee clean Serious injuries or X N Daily exposure 8 Equipment induction done and Production GMR85Sec
OHS 2,3,4,5,7
0f 1993 Sec 8 & 4 5 0 8 72 72 (T)
ONPHS tub filling whilst machine the swelling using a loss of limb. in all tub lines operators trained. SOP 7.5.5.2 loss 14
is running mutton cloth whilst the
machine is running the
cloth or the hand can be Operators have been trained. GMR Sec7(9)
CR Sec 2,3,4,5,7
get caught in the GSR Sec 2
EFP096 machine. can be hit by
Removing untapped box Employee Injury to hand & X N Daily exposure 40 Operators trained .SOP 7.5.5.3 Can possible OHS 85 0f 1993 Sec 8 & 5 5 0 8 80 80
ONPHS from tape sealer a monkey tail whilst fingers. in most lines be cut by 14
removing box from the blades whilst
tape sealer if isolation removing GMR Sec 2,3,4,5,7
is not done untapped CR Sec 7(9)
boxes in the GSR Sec 2
sealer
EFP097 Unarming tubs nesting in If employees are Serious injury. X N Daily exposure 26 Ladders provided and operators n/a OHS
GMR85Sec
0f 1993 Sec 8
2,3,4,5,7 6 4 0 8 80 80 (T)
ONPHS the A frames standing on the top in tub lines trained. CR Sec 7(9)
machine whilst doing
work on A frames
chances are high that Ladder has been added on Line
they can slip from the 12 GSR Sec 6,13
machine and get injured GMR Sec 2,3,4,5,7
especially on the hip
HEALTH
CR Sec 8
Page 72 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP005 Performing normal tasks Visitors & workers not Loss of hearing. X N 86/85 db.Daily 120 Signage, induction, hearing None OHS 85 0f 1993 Sec 8 & 5 3 0 8 64 64 (T)
ONPHH in Normal working complying to hearing exposure protection supplied, medical 14
conditions in new & old protection rules leading surveillance. Verbal warming
hall (line 1-7) & (line 10- to NIHL Cardinal Rules issued.
15)
NIHLR Sec 1-14
EFP013 Normal operation People not using socks Fungicides and X N 12 Hour Shifts 120 Awareness. There is no None OHS 85 0f 1993 Sec 8 & 4 2 0 10 60 60 (T)
ONPHH due to continuous water parasites can and its a daily continuous spillages, but daily 14
spillages causing breed on feet. exposure cleaning. Hose watering not
hygiene risk / incorrect encouraged.
PPE being used
EFP018 Use of Liquid Accidental or work- Health problems X N 8 hrs. 10 kg / 8 PSM -HCS Survey - Crearasa, None GSR
OHS 85Sec 2 Sec 8 &
0f 1993 2 5 0 9 63 63 (T)
ONPHH Flavourants in the related contact or after long term per day MSDS no.F.18 14
Flavour room (Crearasa) inhalation of chemical exposure.
substances from normal
use or spillage
EWR
GSRSec
Sec62,5,7
EFP019 Use of Liquid Accidental or work- Health problems X N 8 hrs. 10 kg / 8 PSM -HCS Survey TW352-cast, None OHS 85 0f 1993 Sec 8 & 2 5 0 9 63 63 (T)
ONPHH Flavourants in the related contact or after long term per day MSDS no. F.17 14
Flavour room inhalation of chemical exposure.
(TW352-cast) substances from normal
EFP021 Adding ink to Date Coder Accidental or work- Poisoning from X N Ink & Solvent: 1 Design of bottle, sealed with foil None GSR
OHS 85Sec 2,5,7Sec 8 &
0f 1993 4 4 0 8 64 64 (T)
ONPHH machine (Linx Marque related contact or product or serious OEL: Butan-2- cap which is only broken once on 14
Ink 1240, Linx Marque inhalation of chemical health problems. one=200ppm- machine, training. All artisans
Solvent 1512) substances from normal 8hr TWA & were trained 29/30 April 03.
CR Sec 7(9)
use or spillage 300ppm - Disposal drum is in place.
15min. 500 ml Constant monitoring and HCSR
GSR Sec SEC1-17
2,5,7
per application supervision of this practice.Linx
Marque Ink 1240, MSDS no. L.12
CR SecSEC1-17
HCSR 7(9)
EFP032 Normal operating Fatigue and monotony Could cause X N 12 hours / 4 160 Tea breaks..Day off None OHS 85 0f 1993 Sec 8 4 4 0 8 64 64 (T)
ONPHH conditions work conditions (on / off injury / property days.Daily CR Sec 7(9)
work) damage. exposure
EFP033 Lifting reel to feed on the If employees are not Back injury or X N Changed hourly 4 SHE talks & posters on proper n/a OHS 85 0f 1993 Sec 8 4 5 0 9 81 81 (T)
ONPHH machine using the right lifting skeletal injury. in Line 7 & 8.In lifting techniques done Basic Conditions of
techniques whilst lifting 500g changed Employment.
the reels every 45
minutes.
Weights of the Hygiene & ergonomic
machines are Surveys
different.
Page 73 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP034 Doing general duties in Employees can be bitten Toxo plasmosis X N Daily exposure 160 Rodents trapping. Pest control n/a OHS 85 0f 1993 Sec 8 & 14 9 1 0 7 70 70 (T)
ONPHH the plant by rodents ,pests, bees which has serious to all in the done
and cats which are effects in a long plant. Cats can
sometimes found in the run, rabies & be found
plant and if bitten or allergies to bees. outside bottling,
touching ,coming in platform facing
contact with cat faeces. H&K and lawn
next to canteen
EFP036 General duties Excessive exposure to Heatstroke or X N Daily exposure 30 Surveys conducted. Medical n/a OHS 85 0f 1993 Sec 8 & 6 1 10 70 70 (T)
ONPHH heat. dehydration. in all EF&P surveillance. SHE Talks. 14
lines.
EFP037 General duties Fatigue which may lead Shift workers X N Daily exposure 30 Rotation of shifts n/a OHS 85 0f 1993 Sec 8 & 14 7 2 0 8 72 72 (T)
ERW Sec 2
ONPHH to injury in all EF&P
lines.
ENVIRONMENT
EFP005 T Tanks process If inlet pipes leaks oil will Contamination of X N 4 tanks .Daily n/a Area bunded and drain in that None Regional Standards for 5 3 0 8 64 64 (T)
ONPHE spray into roof and resource - water. exposure area goes to Rework.If leak industrial effluents GNR
possible ending up in the appears its repaired immediately 3208 of 29 Aug 1969,
stormwater drains National Water Act 36 of
1998 Sec 19, 20, 22,
NEMA Sec 1, 28 (1), (3),
30 (1)a, b,c, (3), (4), (5),
1997 Sec 7(2), 82(1),
compulsory national
509 of 8 June 2001,
Health By-Laws,
Ekurhuleni Metropilitan
Municipality Waste Water
By-Laws
Page 74 of 75
Risk Quantification
Existing Controls
Secondary Risks
Condition N\A\E
Risk / Impact
Environment
Rate 2011
Rate 2010
Risk I.D.
Health
Safety
S+
P+
L+
xF
EFP006 Cleaning of factory Floor washings not Contamination of X N 15 m3 n/a Effluent plant control.Cut off None National Water Act 36 of 5 3 0 8 64 64 (T)
ONPHE Floors properly contained in water - Add to floorwashings drains and when galley is full the 1998 Sec 19, 20, 22,
ground floor (cut off depletion of per day sludge gulper is called to pump NEMA Sec 1, 28 (1), (3),
drains) sending fatty resources. sludge out. Daily inspections 30 (1)a, b,c, (3), (4), (5),
water stormwater drains done. Water Services Act 108 of
1997 Sec 7(2), 82(1),
Regional Standards for
industrial effluents GNR
3208 of 29 Aug 1969,
compulsory national
509 of 8 June 2001,
Health By-LawsEkurhuleni
Metropilitan Municipality
Waste Water By-Law
EFP009 Disposal of hair nets Incorrect disposal of nets Overflow of drains X N Blockage once n/a Housekeeping.Environmental None Environment Conservation 2 6 0 8 64 64 (T)
ONPHE down drains causing lead to waste a quarter awareness done.General waste Act 73 of 1989 Sec 19 (1),
blockages to stormwater resource. bins provided A, NEMA Sec 1, 28 (1),
drains (3), 30 (1)a, b,c, (3), (4),
(5)Regulations relating to
compulsory national
509 of 8 June 2001,
Ekurhuleni Metropolitan
Municipality Solid Waste
By-Laws
Page 75 of 75

Scope: Old & New Packing Hall Department / Plant: Ef&P Review Date

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ABBREVIATIO

Hazard Category / Aspect

No. of People Exposed

No. of People Exposed

X E 32 barrels.Daily 20 HCSR SEC1-17

No. of People Exposed

GSR Sec 2,5,7

Hygene & ergonomic

No. of People Exposed

GSR Sec 5&7

GMS Sec 1,2,3,4,5,6,7

No. of People Exposed

No. of People Exposed

No. of People Exposed

GMR Sec 1,2,3,4,5,6,10

Hygene & ergonomic

No. of People Exposed

No. of People Exposed

No. of People Exposed

GSR Sec 2,5,7

GSR Sec 2,5,7

Page 10 of 75 CR Sec 7(9)

No. of People Exposed

GSR Sec 2,5,7

GMR Sec 2,3,4,5,7

No. of People Exposed

No. of People Exposed

No. of People Exposed

No. of People Exposed

Not Rated in 2010

HEALTH CR Sec 8; Ekurhuleni

No. of People Exposed

NIHLR Sec 1-14

NIHLR Sec 1-14

No. of People Exposed

No. of People Exposed

Page 18 of 75 DMR Sec 18

No. of People Exposed

No. of People Exposed

National Road Traffic

No. of People Exposed

No. of People Exposed

No. of People Exposed

Not Rated in 2010

No. of People Exposed

Not Rated in 2010

Not Rated in 2010Not Rated in 2010

Training (Competent Persons)

GSR Sec 2 & CR Sec

No. of People Exposed

Training (Competent Persons)

Training (Competent Persons)

Training (Competent Persons)

Training (Competent Persons)

Cut on hands and

Training (Competent Persons)

Training (Competent Persons)

Burn with hot

GSR Sec 2 & CR Sec

No. of People Exposed

Training (Competent Persons)

Training (Competent Persons)

Cut on hands and