YAMAZAKI MAZAK SINGAPORE PTE LTD

Risk Assessment Form

Risk Assessment Record
Doc ref: RA_001 Task/Process Assessed: General Warehousing and Production Floor
Revision: 01 Location: Yamazaki Mazak Singapore Pte Ltd
Operation: Forklift & Overhead Crane Operations Assessment Team: Abdul Rashid, Sim Toh Yong, Eric Eu
Date: 01.01.2009 Last Review Date: 01.01.2012 Next Review Date: 01.01.2015 Approved by: Y Togashi

1. HAZARD IDENTIFICATION 2. RISK EVALUATION 3. RISK CONTROL

No Work Activity Hazard Description Possible Accident / ill Existing Risk Control Measure Additional Risk Control Action By

Likelihood

Risk Level
Severity
Health & Persons-at- (If Any) Designation
Risk (Follow-up date)

1. Forklift Operations – 1. Falling of crates from Hit by heavy items - Supervisor to ensure: Supervisory staff to ensure All Supervisory
Loading and Unloading the forklift head, fracture, crush compliance staff
All forklift operators are trained and
injuries licensed; (Constantly)
(Forklift Operator and All personnel are reminded
Worker) constantly be alert at forklift
(Damage to materials) movement area, and to stay clear
from moving forklift; and
Forklift Operator to:

Medium
Remote
Major
Forklift operator to wear safety
shoes;
Do not exceed safe working load of
forklift
Ensure load is properly balance;
No speeding; and
Routes are free of pot-holes and
loose objects
2. Restricted driver Serious injury or death Forklift Operator to: Supervisory staff to ensure All Supervisory
visibility to workers and nearby compliance staff
Sound horn at blind corner; and

Medium
Remote
people due to unknown (Constantly)

Major
incoming traffic Drive slowly at poor visibility area;
and
(Forklift Operator and
Worker) Observe all safety signs
 YAMAZAKI MAZAK SINGAPORE PTE LTD
Risk Assessment Form
1. HAZARD IDENTIFICATION 2. RISK EVALUATION 3. RISK CONTROL
No Work Activity Hazard Description Possible Accident / ill Existing Risk Control Measure Additional Risk Control Action By

Likelihood

Risk Level
Severity
Health & Persons-at- (If Any) Designation
Risk (Follow-up date)

3. Inadequate braking Serious injury or death Forklift Operator to: Supervisory staff to ensure All Supervisory
to workers and nearby compliance staff
Conduct daily pre-operation check
people due to failure to

Medium
Remote
to ensure forklift is in good working (Constantly)

Major
stop forklift condition; and
(Forklift Operator and Ensure forklift is maintenance and
Worker) service regularly.
4. Unauthorised operation Serious injury or death Supervisor to: Supervisory staff to ensure All Supervisory
to workers and nearby compliance staff
Ensure only authorised and trained

Medium
Remote
people due to personnel are allowed to operate (Constantly)

Major
unauthorised operation the forklift.
(Forklift Operator and
Worker)

5. Additional passengers Serious injury or death Forklift Operator to: Supervisory staff to ensure All Supervisory
to additional compliance staff
Ensure no passenger is allowed on

Medium
passengers due to

Remote
the forklift (Constantly)

Major
falling off from forklift
(Passenger)

2. Forklift Movements 1. Inadequate / lack of
regular maintenance of
forklift e.g. Tyres worn out,
no reversing light, horn not
working
2. Losing control of forklift
Serious injuries or Supervisor to: Supervisory staff to ensure All Supervisory
death from skid and compliance staff
Ensure only authorised and trained
overturning of forklift or personnel are allowed to operate (Constantly)
other forklift accidents
the forklift; and
(Forklift Operator and Ensure there is a regular

Medium
Remote
Major
Worker) maintenance program and
due to mechanical
defect e.g. brake fault, servicing by contractor for forklifts.
worn out tyres Forklift Operator to:
Conduct daily pre-operation check
to ensure forklift is in good working
condition;
 YAMAZAKI MAZAK SINGAPORE PTE LTD
Risk Assessment Form
1. HAZARD IDENTIFICATION 2. RISK EVALUATION 3. RISK CONTROL
No Work Activity Hazard Description Possible Accident / ill Existing Risk Control Measure Additional Risk Control Action By

Likelihood

Risk Level
Severity
Health & Persons-at- (If Any) Designation
Risk (Follow-up date)

Ensure route is kept free of

obstruction;
Park at forklift parking area;
Observe “Do not Speed” warning
sign;
Sound the horn and slow down
when approaching corners, or
pedestrians crossing
Other Workers to:
Be alert at forklift movement area,
and to stay clear from moving
forklift

3. Fuelling of forklifts 1. Absence of proper Fire from diesel can Supervisor to: Supervisory staff to ensure All Supervisory
(diesel) refuelling area result in serious injury compliance staff
Ensure refuelling area is provided
or death of workers and with warning signs and proper fire (Constantly)

Medium
Remote
nearby people in the

Major
fighting equipment
presence of ignition
source
(Forklift Operator and
Worker)
2. Flammable materials Fire & explosion in Supervisor to: Supervisory staff to ensure All Supervisory
(diesel) presence of intense compliance staff
Ensure Diesel fuelling is stationed
heat or naked light away from hot work area; (Constantly)
(Forklift Operator and

Medium
Remote
All ignition sources and open flame

Major
Worker) are prohibited at / near refuelling
station; and
Only authorized personnel are
allowed to fuel forklifts
 YAMAZAKI MAZAK SINGAPORE PTE LTD
1. HAZARD IDENTIFICATION
No Work Activity Hazard Description Possible Accident / ill
Health & Persons-at-
Risk
Forklift Operator to:
3. Slippery floor due to Body injuries from slips Forklift Operator to:
leakage or spillage of oil and falls and skin
during fuelling irritation from direct
contact with diesel
(Forklift Operator and
Worker)
1. Overhead Crane 1. Unsafe lifting operation 1. Failure of crane, 1. Shopfloor Technicians /
Operations lifting appliance and
lifting gear; and
2. Incompetent crane
operator and lifting
team can cause
serious injury or
death of workers
working nearby.
3. Safety devices not
functioning
4. Poor maintenance of
crane
Risk Assessment Form
2. RISK EVALUATION 3. RISK CONTROL
Existing Risk Control Measure Additional Risk Control Action By
Likelihood
Risk Level
Severity
(If Any) Designation
(Follow-up date)
Observe “No Smoking” rule at the
fuelling area
Supervisory staff to ensure All Supervisory
compliance staff
Wear safety shoes and gloves; and
Moderate
Remote
(Constantly)
Low
Clean-up all spill promptly.
1. Lifting Supervisor to: Lifting
Engineers to: Prepare lifting plan, RA Supervisor,
Conduct daily check on the and ensure that the LM Shopfloor
cranes prior to use to ensure that and LG have valid Technicians,
it is in good operating condition; certificates; Engineers, and
Workshop
All cranes and lifting gears must Train all shopfloor Manager
have a valid certificate issued by technicians / engineers
an Authorized Examiner; and other personnel on
how to operate the crane
All cranes shall be inspected
Occasion
yearly / half yearly by an prior to allowing them to
Minor
Low
Authorized Examiner and load using it.
tested once every four (4) years;
Crane is maintained by an
experienced technician and
preventive maintenance is carried
out annually;
Factory designed lifting gears are
used to lift the CNC machines,
machine beds and parts;
 YAMAZAKI MAZAK SINGAPORE PTE LTD
Risk Assessment Form
1. HAZARD IDENTIFICATION 2. RISK EVALUATION 3. RISK CONTROL
No Work Activity Hazard Description Possible Accident / ill Existing Risk Control Measure Additional Risk Control Action By

Likelihood

Risk Level
Severity
Health & Persons-at- (If Any) Designation
Risk (Follow-up date)

2. Positioning of crane 1. Congested workplace 1. Crane can hit 1. Shopfloor Technicians / Nil Shopfloor
object or cause Engineers to: Technicians /
serious injury to Check clearance of the passage Engineers

Occasion
personnel at site way before allowing the crane to

Minor

Low
during manoeuvring manoeuvre; and
e
Demarcate/barricade the
operation area with warning sign
to keep others away
3 Rigging of load 1. Falling object caused by 1. Falling object can 1.Shopfloor Technicians / Nil Shopfloor

Occasion
use of faulty lifting gear strike personnel Engineers to carry daily pre- Technicians /

Minor

Low
/appliances standing below operation inspection of lifting Engineers
appliances and gears.

2. Falling object caused by 1. Falling object can 1.Shopfloor Technicians / Nil Shopfloor
improper rigging of load strike personnel Engineers to check and ensure Technicians /

Occasion
standing below load is properly rigged Engineers

Minor

Low
2.Ensure no persons stands
underneath a lifted load

3. Overloading of crane 1. Crane can collapse 1. Shopfloor Technicians / Nil Shopfloor

(Load may exceed rated onto workshop Engineers to: Technicians /

Occasion
capacity of the crane) equipment and Engineers

Minor
Check weight of the load to be

Low
personnel lifted and ensure that it does not
exceed the SWL of the crane.

4 Lifting of load over 1. Falling object 1. Falling object can 1. Shopfloor Technicians / Nil Shopfloor
other work activities strike personnel Engineers to: Technicians /
area standing below Warn other personnel and keep Engineers

Occasion

Minor

Low
them away from lifting area;
Roping off area with warning sign;
Sound the alarm to warn nearby
personnel.