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❖ Warehouse Management Plan

❖ M. Saeed Sajjad
Case Study Report – Admin Specialist
Warehouse Management Plan

Table of Contents
1.0 Introduction ................................................................................................................................ 1
2.0 Warehouse Management Plan .................................................................................................... 1
2.1 Warehouse Organization Chart ......................................................................................................... 2
2.2 Warehouse Arrangement / Space Management And house keeping ................................................ 3
2.2.1 Warehouse Arrangement / Space Management ........................................................................................... 3
2.2.2 Housekeeping in Warehouse ......................................................................................................................... 4
2.3 Inventory Listing / Tracking Mechanism ........................................................................................... 5
2.4 Receiving and Managing New Stock.................................................................................................. 5
2.5 Establishing EHS Protocols ................................................................................................................ 5
2.5.1. Vehicle Safety Protocols................................................................................................................................ 5
2.5.2. Slips, Trips, and Falls ..................................................................................................................................... 6
2.5.3. Fire Safety ..................................................................................................................................................... 7
2.6 Communication Plan ......................................................................................................................... 7
2.6.1. Creating a Clear Communication Structure .................................................................................................. 8
2.6.2. Providing Wearables for Staff ....................................................................................................................... 8
2.6.3. Installing Radio System ................................................................................................................................. 9
2.6.4. Installing PA (Public Address) System ........................................................................................................... 9

3.0 Risk Assessment and Mitigation Plan ........................................................................................ 10


3.1 Risks identification .......................................................................................................................... 11
3.2 Risks Measurement......................................................................................................................... 12
3.3 Examining Solutions ........................................................................................................................ 15
3.4 Implementing Solutions And Monitoring Results............................................................................ 18

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Case Study Report – Admin Specialist
Warehouse Management Plan

List of Figures
Figure 2:1: Warehouse Management Plan......................................................................................................... 1
Figure 2:2: Warehouse Organization Plan.......................................................................................................... 2
Figure 2:2: Warehouse Arrangement Plan ......................................................................................................... 3
Figure 3:1: Risk Management Process ............................................................................................................. 10
Figure 3:1: Risk Involved in Warehouse Operations ......................................................................................... 11

List of Tables
Table 3-1: Measurement of Associated Risks with Warehouse Operations ...................................................... 12
Table 3-1: Solutions of Associated Risks with Warehouse Operations .............................................................. 15

Prepared by: M. Saeed Sajjad ii | P a g e


Case Study Report – Admin Specialist
Warehouse Management Plan

1.0 INTRODUCTION
This document provides a complete execution plan for successfully managing all the daily tasks of
warehouse management by devising a Warehouse Management Plan, Communication Plan,
Associated Risks and its Mitigation Plan. These plans will consider all the aspects involved in warehouse
management however will keep a special focus on the issues at hand i.e., poor housekeeping, water
leakages and to control EHS (Environment health and Safety) violations.

2.0 WAREHOUSE MANAGEMENT PLAN


The project management plan (PMP) will be comprised of the following components:

• Warehouse Organization Chart


• Warehouse Arrangement / Space Management Plan
• Inventory Listing / Tracking Mechanism
• Protocols for Receiving and Managing New Stock
• Measuring Warehouse Overall Performance
• Establishing EHS (Environment Health and Safety) Protocols
• Communication Plan
• Risk Assessment and Mitigation Plan

Organization Chart

Space Management Plan


Warehouse Management Plan

Inventory Listing

Protocols for Receiving


and Managing New Stock

Warehouse Overall
Performance

EHS Protocols

Communication Plan

Risk Assesment &


Mitigation Plan

Figure 2:1: Warehouse Management Plan

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Case Study Report – Admin Specialist
Warehouse Management Plan

2.1 WAREHOUSE ORGANIZATION CHART


Following is the complete network of all the departments of involved in operating the warehouse successfully.

Warehouse Management
Departments

Maintenance
Storage Dept. Business Dept. EHS Dept. Quality Dept. Security Dept.
Dept.

Support & Sale & Planning /


Commuinication
Operations Procurement Finance Dept. Maintenance
Dept.
Dept. Dept. Dept

Fire Fighting
IT Dept.
Dept.

House Keeping
Data Dept.
Dept.

Inventory Dept.
Figure 2:2: Warehouse Organization Plan

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Case Study Report – Admin Specialist
Warehouse Management Plan

2.2 WAREHOUSE ARRANGEMENT / SPACE MANAGEMENT AND HOUSE KEEPING


2.2.1 Warehouse Arrangement / Space Management
The objective here is to arrange the available space in such a way to address the following factors:

• Provision of enough space for inventory


• Provision of adequate working space for staff to carry out the routine tasks.
In order to achieve the above-mentioned objectives, the warehouse shall be divided into the
following areas:

• New Stock Receiving Area


• Unpacking and booking in new stock Area.
• Warehouse Office
• Main Storage Area
• Excess / Obsolete Stock Storing Area
• Packing Area
• Shipping / Discharge Area

Figure 2:3: Warehouse Arrangement Plan

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Warehouse Management Plan

The business development and research team will be responsible to analyse the customer demand and
provide with the list of items which have the highest demand. This data shall be utilized in arranging
the items. The higher the demand the higher the accessibility to the staff in the lowest possible time.
Thus, putting the higher demand items near the Dispatch (Shipping Pickup) area will be recommended.

2.2.2 Housekeeping in Warehouse


In order for the warehouse to work efficiently the housekeeping services plays a very important role.
The house keeping is not only about cleaning or sweeping up the floors, rather when it comes to a
warehouse the duties become much more safety oriented. Due to the fact that the warehouse
activities act as magnet for the incidents to happen therefore good housekeeping will ensure lower
chances of accidents.

The house cleaning activities in a warehouse could be broadly divided into the following categories:

➢ Warehouse Aisles and Passageways Cleaning


➢ Removing Slip, Trip and Fall Hazards
➢ Waste Material Disposal
➢ Hazardous Materials Disposal
The health and safety team of the warehouse shall conduct training programs on regularly basis to
provide the necessary training to the house keeping staff for conducting the cleaning process safely.
The warehouse management team shall ensure that the necessary workforce required to clean the
warehouse is provided and the supervisors of the housekeeping team shall ensure that the cleaning
team is working in the designated areas and are working effectively. The cleaning workers shall fill out
the Performa indicating that all the cleaning activities mentioned have been carried out. These
Performas shall be checked, signed and submitted by the supervisors. The workers not fulfilling their
jobs or not performing up to the mark shall be notified and if required replaced.

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Warehouse Management Plan

2.3 INVENTORY LISTING / TRACKING MECHANISM


A complete list of inventories shall be maintained. All the items should be tagged and an inventory
management system shall be used tag the items in order to have the total number of available items
as per each inventory list.

The tagging system shall include the warehouse area number, Row number, Shelve Number, And Bin
Number. All the items coming in or out of the warehouse shall be tagged and the inventory list shall
be updated on daily basis.

2.4 RECEIVING AND MANAGING NEW STOCK


The receiving and managing new stock shall be efficient enough or else any delay in this process will
highly jeopardize the overall operation. Following key factors shall be considered:

• Appropriate Availability of Space in Receiving Area


• Distribution of Assignments to workers for quick stock processing
• Recording and Keeping Track of all Items Received
• Inspection of new Stock
• Tagging of all the items as per the Inventory Guidelines
• Update the Inventory and store in the relevant warehouse space

2.5 ESTABLISHING EHS PROTOCOLS


Warehouses contain many hazards and opportunities for accidents and
injuries. Warehouse hazards can change from moment to moment,
depending on the tasks employees are performing, the equipment they’re
using, and the materials they’re handling. Employees must understand the
hazards and precautions in order for the warehouse to have a safe working
environment. The EHS team shall perform the following activities to ensure
the safety of everybody:

2.5.1. Vehicle Safety Protocols


Following protocols shall be followed:

✓ Only allow staff to drive vehicles if they have


received practical training
✓ Ensure workers maintain speed limits
✓ Ensure staff avoid reversing wherever
possible
✓ Maximize visibility
✓ Enforce a zero-tolerance policy for dangerous driving, such as racing.

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Warehouse Management Plan

✓ Keep aisles free of obstructions


✓ Arrange for regular inspection and maintenance of vehicles.
✓ Provide drivers with a list of daily checks
✓ Display driver safety notices and signs.
✓ Maintain the floor to prevent overturning or damage to the vehicle

2.5.2. Slips, Trips, and Falls


Following protocols shall be followed:

✓ Ensure staff know how to carry out good WAREHOUSE SAFETY SIGNS
housekeeping.
✓ Ensure cleaning staff display appropriate
warning signs. Try to schedule cleaning
outside of normal work hours so it puts
fewer people at risk. Also make sure that
cleaners use the correct method and
detergent for your type of warehouse floor.
✓ Use anti-slip paint. It prevents dust from
building up, reduces the slip quality of the floor surface, minimises wear and tear, and improves
cleaning.
✓ Use anti-slip tape and shoes. Tape is useful for stairs and other areas where you can’t use anti-
slip paint, while non slip soles help people remain safe even if they do encounter a slip hazard.
✓ Make sure floors are level – uneven flooring can cause people to lose their footing. This is
especially dangerous if they’re carrying a load.
✓ Use heavy-duty cord covers if you must run cables across the floor. As well as preventing trips,
covers also protect cables in case a vehicle runs over them.
✓ Train staff to work at height safely. Ladder safety is particularly important because misuse or
use of an unstable ladder can lead to serious injury or even death. Make sure workers maintain
three points of contact at all times (e.g., two feet and one hand).

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Case Study Report – Admin Specialist
Warehouse Management Plan

2.5.3. Fire Safety


To maintain fire safety, you should:

✓ Carry out fire drills at least once a year. Drills help


you check that your escape routes work in practice.
They should demonstrate that staff know the
location of fire exit routes and the assembly point.
✓ Test fire alarms weekly and check smoke alarms
ideally on a monthly basis. Also check other
equipment regularly, such as extinguishers and
sprinklers.
✓ Create a fire evacuation and emergency plan. You should review and update it regularly.
✓ Designate a fire warden. Their responsibilities include minimising fire hazards in the workplace,
creating evacuation plans, and taking charge during an emergency.
✓ Ensure you have installed emergency lighting. Fire escape routes, exits, and signs need to be
well-lit so people can see them from a distance and navigate safely.
✓ Handle materials safely. Staff need to ensure they clear away boxes and packaging and handle
hazardous substances with extreme care. Make sure they know how to store chemicals safely
in a warehouse.

To enforce the above-mentioned safety protocols, it is the responsibility of the safety team to prepare
the checklists and make available to the staff. It shall be made mandatory for the staff to fill all the
required checklists before commencing the process. In addition, the safety officers shall make surprise
visits to various departments and issue the NCR (Non-Compliance Report) to the persons not following
the safety protocols. The same NCR shall be updated in the personal file of each employee. The
employee making consistent violation of the safety protocols shall be notified for severe action and if
improvement observed shall immediately be fired for the overall well-being of the warehouse.

2.6 COMMUNICATION PLAN


In order to carryout the daily warehouse operations without any hurdle good communication between
the workers is the key. Therefore, it is indeed needed to have a communication plan such that
managers can optimize communication within their warehouses through the use of various tools and
techniques, some advanced and some pragmatic. One thing is for sure. However, bettered
communication is sure to increase your factory’s output and overall productivity levels.

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Case Study Report – Admin Specialist
Warehouse Management Plan

Installing
Clear Wearables
Radio PA System
Structure for Staff
System

Figure 2:4: Warehouse Communication Plan

Following are the main components of a communication plan recommended for warehouse:

2.6.1. Creating a Clear Communication Structure


One of the first steps to improving communication is making sure there's a clear chain of command.
When issues pop up, staff need to know who they should contact about the problem and from whom
they can get advice or action steps. The right actions can be taken when staff members know who they
should contact based on the nature of the problem and how they can contact those people quickly.

In addition to ensuring staff know who to contact, managers should prioritize setting up regular in-
person meetings and check-ins with staff. Speaking to staff members face to face is one of the best
ways to communicate information. When new policies or procedures are being implemented, the
managers shall conduct a meeting with staff individually or hold special in-person meetings for
management to communicate the changes.

2.6.2. Providing Wearables for Staff


Warehouses can be huge, and as a result, it can be difficult for staff members to find each other's
location and get in contact with each other. A great way to keep track of employees and facilitate faster
communication is outfitting key staff members with wearable devices. Wearable devices are usually
worn on a wrist or hip and feature GPS technology showing viewers where the device is at all times.
When staff members wear these devices, supervisors and managers can quickly locate employees they
can't reach otherwise. They can also use the devices to delegate responsibilities or other tasks to
employees based on their proximity to a department or work station.

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Case Study Report – Admin Specialist
Warehouse Management Plan

2.6.3. Installing Radio System


Installing a radio system is the most effective way of
communication between the workers and it entails the
following benefits:

Quick & efficient resolution of problems

• More effective collaboration & coordination


• Increased workforce productivity
• Improved worker safety & emergency preparedness

In addition to communication the safety features on two-way radios perhaps are of the utmost
appeal in these high-risk work environments, as they often include the following three programs.

• Man Down: A built-in sensor detects when the radio is in a horizontal position, suggesting the
worker has collapsed, and sending a signal across the channel.
• Lone Worker: When a worker has not interacted with the radio for a while, it will send a
reminder signal to ensure their safety. If no response, it will alert the radio operator.
• Emergency Button: If a worker is in immediate danger, they can press one button to sound an
alarm across the channel indicating trouble.

2.6.4. Installing PA (Public Address) System


Managers and supervisors can use PA systems to quickly get the attention of all workers at once and
give them critical information.

The PA system speakers can be set up all around the warehouse so it's possible for everyone to hear
key messages. Ensuring PA announcements are reserved for key messages and only accessible by
responsible personnel can prevent false alarms from going out or the PA system being overused,
causing people to tune out the messages.

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Case Study Report – Admin Specialist
Warehouse Management Plan

3.0 RISK ASSESSMENT AND MITIGATION PLAN


From a warehouse point of view there could be various factors and potential reasons which may cause accidents or
jeopardize the operations. Therefore, it is of very important to consider all the risks associated with the warehouse
activities and prepare a mitigation plan. In order to formulate a mitigation plan following work flow shall be
followed:

Identify
Risks

Monitor Measure
Results Risks
Risk
Management
Process

Implement Examine
Solutions Solutions

Figure 3:1: Risk Management Process

In the light of the above risk assessment has been carried out while considering the operations involved in the
warehouse. The main operations having the highest risk factors are considered. Following are areas considered for
risk management:

1. Risks involved in the Storage


2. Operational Risks
3. Maintenance Risks
4. Procurement Risks
5. Security Risks

A complete assessment along with the mitigation plan has been provided in the following section.

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Case Study Report – Admin Specialist
Warehouse Management Plan

3.1 RISKS IDENTIFICATION


The first step is identifying all the potential risks involved in the warehouse operations. Following are some of the risks involved categorized for each operation
type:

Risks Identification

Storage Risks Oprational Risks Communication Risks Maintenance Risks Procurement Risks Security Risks Miscellaneous Risks

Slip/Trip Falling Radio System


Electricity Failure Building Damages Unavailability of Internal Thefts Fire
of Staff and Failiure
Material
Material
Machinery Fire System
Fire/Short Circuit External Thefts Flooding
Failure Failure
in Radio Room Fraudulent/Scams
Accidents While
Using Machinery Shelving Units
Data Loss Natural Clamity
Damages

Accidents Due to IT System Failiure Electricity Failure


Hazardous
Materials
Water Leakages

Unavailability of
Storage Space Accidents Due to
Poor Housekeeping

Improper Storage

Figure 3:2: Risk Involved in Warehouse Operations

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Warehouse Management Plan

After the identification of the risks all the risks shall be measured. Meaning, that all the risks shall be evaluated based on the occurrence and the impact of the
risk.

3.2 RISKS MEASUREMENT


This section provides a detailed analysis of the above-mentioned risks. All the risks have been evaluated on the basis of their occurrences and the level of
impact they cause on the overall operation.

Table 3-1: Measurement of Associated Risks with Warehouse Operations

Failure Mode /
Part/Process Failure Effect Causes Severity Occurrence Detection
Risk
Poor Housekeeping
Staff Injury / Damaged
Slip/Trip Falling Poor Use of Lifting Machinery HIGH HIGH HIGH
Material
Unsafe use of Ladders
Machinery Failure
Accidents while Using Staff Injury / Damaged
Faulty machinery HIGH HIGH HIGH
Storage of Machinery Material
Materials Human Error

Accidents due to Staff Injury / Damaged Mishandling of Material


HIGH HIGH HIGH
Hazardous Materials Material
Poor Housekeeping
Unavailability of Storage Warehouse Operation
Poor Space Management HIGH LOW HIGH
Space Failure
Poor Electricity Circuits
Warehouse Operation Short Circuits
Electricity Failure HIGH LOW HIGH
Failure Generator System
Operational
Malfunction
Risks
Warehouse Operation Faulty Machinery
Machine Failure Failure, Warehouse HIGH HIGH HIGH
Operation Failure
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Failure Mode /
Part/Process Failure Effect Causes Severity Occurrence Detection
Risk
Human Error
Short Circuits
Warehouse Operation
Data Loss Unavailability of Backups HIGH LOW LOW
Failure,
Cyber Attacks
Overheating of IT servers due
Warehouse Operation to poor Cooling System
IT System Failure HIGH MEDIUM LOW
Failure, Poor Cyber Security
Unavailability of Backups
Central Radio System
Communication Warehouse Operation Malfunction
Radio System Failure HIGH LOW LOW
Risks Failure,
Human Error
Staff Injury / Damaged Untreated Structural
Material Damages
Building / Storage
Disturbance in HIGH LOW LOW
Shelves Damages Improper Maintenance
Warehouse
Operations Techniques

Staff Injury / Damaged Improper QAQC checks


Material Unavailability or Expired Fire
Maintenance Fire System Failure HIGH LOW LOW
Warehouse Operation Fighting Equipment
Risks Failure Untrained Crew
Staff Injury / Damaged Poor Water Supply System
Water Leakages HIGH HIGH HIGH
Material Poor Maintenance of Piping
Disturbance in Poor Procurement Planning
Procurement Unavailability of
Warehouse Shortage of Material in Open HIGH LOW LOW
Risks Materials
Operations Market

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Warehouse Management Plan

Failure Mode /
Part/Process Failure Effect Causes Severity Occurrence Detection
Risk
Improper Scrutiny of the
Fraudulent / Scam Financial Burden HIGH LOW LOW
Supplier
Unavailability / Inefficient
Surveillance System
Security Risks Internal / External Thefts Financial Burden HIGH MEDIUM HIGH
Insufficient Number of
Security Personnel’s
Miscellaneous Flooding, Earthquakes, Warehouse Operation
Natural Calamity HIGH LOW LOW
Risks Other Natural Calamity Failure,

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Warehouse Management Plan

3.3 EXAMINING SOLUTIONS


Once all the risks are identified and measured next is to implement the required counter system to ensure that the impact of the risk could
be reduced if not nullified completely so that all the operations could run smoothly. Following table provides the solutions to each risk:

Table 3-2: Solutions of Associated Risks with Warehouse Operations

Part/Process Failure Mode / Risk Causes Solutions


Poor Housekeeping
Poor Use of Lifting
Slip / Trip Falling Conduct Proper Training of the staff
Machinery
Unsafe use of Ladders

Machinery Failure
Enhance the QAQC checks and train the staff
Accidents while Using
Storage of Machinery Faulty machinery
Materials Proper training of staff and making sure that adequate rest
Human Error
periods is provided to the staff
Enhance the Material Handling Protocols, Increase housekeeping
Accidents due to Mishandling of Material
staff (If deficient)
Hazardous Materials
Poor Housekeeping Provide proper training, Implement strict compliance policy
Improve the space management systems by using inventory
Unavailability of
Poor Space Management software to reduce the processing and storage time. Increase the
Storage Space
resources (man + equipment) if not sufficient
Implementing QAQC checking mechanisms and replacing the
Poor Electricity Circuits
faulty circuits at the earliest
Operational
Electricity Failure Short Circuits Installing the safety features such as fuses etc.
Risk
Generator System
Daily checking the generator system
Malfunction
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Warehouse Management Plan

Part/Process Failure Mode / Risk Causes Solutions


Faulty Machinery
Machine Failure Enhance the QAQC checks and train the staff
Human Error
Implementing QAQC checking mechanisms and replacing the
Short Circuits
faulty circuits at the earliest
Data Loss
Unavailability of Backups Making sure to install a secured automatic data backup system
Cyber Attacks Making sure to install and keeping the firewall system updated
Overheating of IT servers Seal air leaks in the ducts.
due to poor Cooling Be sure that vents and return vents are unobstructed
IT System Failure System Hire a certified air duct cleaning professional.
Poor Cyber Security Making sure to install and keeping the firewall system updated
Unavailability of Backups Making sure to install a secured automatic data backup system
Central Radio System
Communication Continuous monitoring and testing of central radio system
Radio System Failure Malfunction
Risks
Human Error Provide proper training
The maintenance team shall have a preventive approach rather
Untreated Structural
than reactive thus treating the minor structural defects
Building / Storage Damages
beforehand should be of utmost priority
Shelves Damages
Improper Maintenance
The maintenance team shall have experienced professionals
Maintenance Techniques
Risks Improper QAQC checks The EHS team shall ensure the following:
- Daily testing of the firefighting system
Unavailability or Expired
Fire System Failure - Testing of Fire Extinguishers and replacing the expired ones
Fire Fighting Equipment
- Conducting Weekly of at least monthly firefighting mandatory
Untrained Crew drills

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Warehouse Management Plan

Part/Process Failure Mode / Risk Causes Solutions


The maintenance team shall ensure the following:
- Testing of water supply system
Poor Water Supply System
- Identifying the sources of water leakages
Water Leakages
- Installation of sensors and meters
Poor Maintenance of
Using good quality and durable pipes for plumbing
Piping
The business development team shall ensure the following:
Poor Procurement
- Analysing the market demands and informing the procurement
Unavailability of Planning
team for the necessary materials
Materials
Procurement -Timely Informing the procurement team abouts the required
Shortage of Material in
Risks materials
Open Market
Before finalizing any new supplier, the procurement team along
Improper Scrutiny of the
Fraudulent / Scam with the security team shall ensure that the supplier is legit and
Supplier
not a fraudulent.
The security department shall ensure the following:
Unavailability / Inefficient - Electronic security and surveillance systems
Internal / External Surveillance System - Employee checks
Security Risks
Thefts - Visitor sign-in registers
Insufficient Number of Check and assess the security guards required to ensure the
Security personnel safety of staff and material
Miscellaneous Flooding, Earthquakes, Looking at the available historic data and developing the
Natural Calamity
Risks Other Natural Calamity emergency plans.

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Case Study Report – Admin Specialist
Warehouse Management Plan

3.4 IMPLEMENTING SOLUTIONS AND MONITORING RESULTS


Planning without implementation is totally vain. This portion of the case study deals on how to
successfully implement the risk mitigation plan. In addition to implementation consistent monitoring
of the systems is also required to ensure that the required results are obtained or the existing systems
requires some modifications.

Following steps shall be taken to ensure the successful implementation:

➢ The proposed risk management plan shall be circulated to all the concerned departments.
➢ Implementation of all the proposed CHANGES in the existing processes.
➢ All the accidents / EHS violations shall be noted down and a detailed report shall be generated
highlighting the underlining cause and the necessary steps taken to rectify the issue.
➢ All the EHS checklists shall be printed and handed over to the supervisors it shall be ensured
that all staff shall adhere to the protocols and methods defined in the checklists.
➢ Realtime effectiveness checking of risk response mechanisms. If the results are not up to the
par, then it’s time to re-evaluate the system and revise the necessary mechanisms.
➢ Remember that success always originates via learning from the failures therefore a lesson
learnt register shall be maintained by all the team leaders and shall discuss in the meetings.
Any suggestion from the team shall be encouraged.

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