Unit IG2: Risk assessment

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

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

Part 1: Background

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

Topic Comments
Name of organisation* Maple Leaf Cement Factory (Known as MLCF)
Site location* Iskandarabad, District Mianwali, Punjab, Pakistan
Number of workers 4000+ (included 1239 workers of Line-1 where assessment is conducted)
General description of the organisation Maple Leaf Cement Factory is one of the largest manufacturer of Pakistan. It is established in
1956 by state of Pakistan but later on in 1992 it was acquired by Saigol Group under privatisation
scheme from Government of Pakistan. It is ISO 9001 and 14001 certified. Company is listed and
traded on Pakistan Stock Exchange.
Main cement products of MLCF included Ordinary Portland Cement (OPC), Sulphate Resistant
Cement (SRC) and White Cement.
There are Cement Lines (Plants) called Line-1, Line-2 and White Cement Plant. Assessment is
done at Line-1 of MLCF. The activities performed at LINE-1 are Crushing of Lime stones and
Gypsum at Crusher, Grinding of raw material at Raw Mill, Buring at Kiln, Clinkers Cooling at
Cooler, Grinding of Clinker at Cement Mill, Packing and Cement Loading.
Workers perform their tasks in 4 Shifts. Timings and patterns of these shifts are:
General Shift (0800-1600) Morning shift (0600-1400)
Evening shift (1400-2200) Night shift (2200-0600)
Number of workers in General shift is 72 and in remaining 3 shifts the number of workers in each
shift is 330. As plant runs for 24/7 therefore workers are offered one rest day (Off) in a week on
different days. 177 workers are on rest everyday at their turn as per their choice and feasibility.

Learner number: 00803531 Learner name: Mazhar Ali Khan Page 1 of 17

 Food breaks are provided in each shift. Most of the workers are in age group of 25 to 45 years.
Description of the area to be included in the Crushing of Lime stones and Gypsum at Crusher, Grinding of raw material at Raw Mill, Buring at
risk assessment Kiln, Clinkers Cooling at Cooler, Grinding of Clinker at Cement Mill, Packing and Cement Loading.
Manager HSE was responsible for health and safety activities and reported to Director
Any other relevant information
Operations.
* If you’re worried about confidentiality, you can invent a false name and location for your organisation but, all other information provided must be
factual.

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

Note: this section can be completed after you have competed your risk assessment.
Outline how the risk assessment was carried
out this should include:
 sources of information consulted;
 who you spoke to; and
 how you identified:
- the hazards;
- what is already being done; and
- any additional controls/actions that To identify and figure out hazards, I visited the plant with the “Manager HSE” and he referred me
may be required.
It is very crucial to have knowledge of Health and Safety before conducting a risk assessment.
Therefore before starting my risk assessment I have visited the website of ILO to collect pertinent
data : https://www.ilo.org/global/standards/subjects-covered-byinternational-labour-standards/
occupational-safety-and-health/lang--en/index.htm , I also browsed at
https://www.hse.gov.uk/non-metallic-minerals/cement.htm , Notes of Learning Partner, RRC IG2
Book.
to the HSE supervisor, I also discussed my findings with field supervisors, shift engineers, and
workers to figure out details that my visual evaluations missed.
To find out what is already being done, I also went to the office of Manager HSE, he provided me
the plant internal data regarding inspections, audits, accidents, incidents, near misses and
illnesses reported for last 12 months.
In search of additional control measures, I have found ILO conventions very informative like
convention on manual handling https://www.ilo.org/dyn/normlex/en/f?
p=NORMLEXPUB:12100:0::NO::P12100_ILO_CODE:C127 , work at confined space
https://www.ilo.org/global/topics/labour-administration-inspection/resources-library/publications/
guide-for-labour-inspectors/working-in-confined-spaces/lang--en/index.htm . I have also found
more crucial data on Portland Cement Dust at:
https://www.hse.gov.uk/pubns/web/portlandcement.pdf and Controlling Noise At Work at
https://www.hse.gov.uk/pubns/books/l108.htm .

Learner number: 00803531 Learner name: Mazhar Ali Khan Page 2 of 17

 Part 2: Risk Assessment
Organisation name: Maple Leaf Cement Factory
Date of assessment: 11th Dec, 2023
Scope of risk assessment: Crusher, Raw Mill, CCR, Preheater, Kiln, Clinkers Cooler, Cement Mill, Packing and cement Loading Area
Hazard category and
hazard
1. Manual
Handling:
The physical activity of
lifting, pulling, pushing as
well as handling heavy
bags of cement and or
other material is observed
in the cement plant.
These kinds of activities
may lead to physical
injuries specifically back
bone injury.
2. Noise:
Heavy machines and
motors with 1000 KW
rating were used in
cement plants for grinding
and crushing purposes,
Learner number: 00803531
Who might be harmed What are you already What further controls/actions are Timescales for Responsible
and how? doing? required? further actions person’s job
to be title
completed
(within …)
Workers that are involved Workers carried the 1. Overhead cranes installation, 1. 2 Months Plant
in the transportation, weight in groups rather forklifts, and other mechanical aids Manager (1,2)
packaging, stacking, than individually to to minimize manual handling. 2. 1.5 Month
unloading, and loading of reduce the danger of 2. Conveyors installation to improve Department
heavy cement bags. harm. manual handling. 3. 2 Weeks Heads (3)
3. To reduce repetitive movements,
Workers being observed in Workers are given job rotation programs need to be 4. 3 Weeks Manager HSE
the MLCF were carrying good-grip safety gloves. implemented. (4)
heavy loads by manually, 4. Manual handling training 5. 5 days
which is the cause of introduction to train all workers on Manager
different health issues like proper lifting tasks. Stores (5)
musculoskeletal disorders, 5. Safety shoes must be provided to
fractures, back bone pain, workers.
joints dislocation,
tendonitis, and
psychological strain.
The loudest noise was felt An out-of-date but 1. Construct soundproof enclosure 1. 01 Month Plant
by field workers, working silencing covering noisy machinery to absorb Manager (1)
equipment operators, system is installed. noise and install vibration isolators 2. 01 Week
tourists, and contractors. to decrease noise transmission. Manager
MLCF offers personal 2. Change the noisy cooling fan with 3. 01 Month Mechanical
Workers, operators, protective equipment a new one. (2)
visitors, and contractors. (PPE) like ear plugs to 3. Noise-producing machinery must
Learner name: Mazhar Ali Khan Page 3 of 17
 Hazard category and
hazard
whereas cooling fans at
the clinker cooler were
running at full RPMs,
producing a lot of noise of
90 dB and more too.
3. Vibration:
Heavy machinery like
crushers, raw mills,
blowers, cooling fans,
revolving cement mills,
and drill machines
operated by workers
produces the vibration.
Learner number: 00803531
Who might be harmed What are you already What further controls/actions are Timescales for Responsible
and how? doing? required? further actions person’s job
to be title
completed
(within …)
They are exposed to noise safeguard their safety. be overhauled and maintained on a 4. 02 Weeks Shift
levels of 90 dB or higher regular basis. Supervisor
for and the whole shift at 4. Check the noise level in each 5. 01 Week (3,4)
the Main Crusher, Cement crushing and grinding zone to
Mill, and Cooling fans may confirm it is within acceptable limits. Dept Heads
suffer from physical effects 5. Execute a worker rotation policy (5)
such as Tinnitus, in all places.
Temporary Threshold
Shift, Noise Induced
Hearing Loss (NIHL).
Vibration will affect all In various sections, like 1. Replace any equipment that is 1. 01 Month Manager
workers, contractors, and the crusher, kiln, and producing extreme vibration with Mechanical
visitors. mill, vibrometers are vibration-resistant ones. 2. 1.5 Month (1,2)
installed to verify and 2. The maintenance of machines
Vibration caused by monitor vibration value, that are generating the intense 3. 01 Month Manager I&C
rotating machinery, and auto-tripping is vibrations need to be done (3)
crushers, mills, blowers, interlocked at the above appropriately and timely 4. 03 Weeks
conveyors, and poor value. 3. Vibrometers must be installed HSE
maintenance of machinery with blowers and cooling fans, and 5. 05 days Supervisor (4)
and drill machines used by Workers are taught how their auto tripping interlocking is
workers. Long-term to handle portable drill required. Manager
vibration exposure causes equipment correctly. 4. Teach workers to utilize the bare Stores (5)
major health issues in minimum of force required to run the
workers, like whole-body A suitable work drill safely.
vibration impacts or hand schedule is intended to 5. Personal protective equipment
arm vibration issues. provide workers with (PPE) like anti-vibration gloves and
relaxation and breaks. safety shoes with specially designed
soles to reduce the influence of
Workers are given the vibration
safety gloves and safety
shoes.
Learner name: Mazhar Ali Khan Page 4 of 17
 Hazard category and
hazard
4. Hazardous
substances:
The atmosphere seen
throughout the factory
was dusty. Cement plant
dust comprises the
emission of harmful gases
such as, CO, No and SO2
as well as small particles
of Silica, Limestone, and
Clay. Inhaling these
gases introduced into the
air during mining,
crushing, and grinding,
and extended exposure to
cement dust, causes
chronic lung and skin
illnesses
5. Slips and Trips:
I've seen oil spills, uneven
ground and restricted
pathways as potential
causes of slip and trip
dangers in cement
facilities.
Learner number: 00803531
Who might be harmed What are you already What further controls/actions are Timescales for Responsible
and how? doing? required? further actions person’s job
to be title
completed
(within …)
Dust exposure might affect To catch dust particles, 1. Installation of bag filter in Packing 1. 01 Month Manager
workers, contractors, a few dust collectors Area of Cement Plant. Plant (1,2)
tourists, and surrounding (bag filters) are placed. 2. A bag house is required on each 2. 01 Month
neighbours. manufacturing area. Manager
Gas analysers are fitted 3. Coverage is required for long belt 3. 02 Weeks Mechanical
They inhale poisonous to monitor harmful gas conveyors that transport crushed (3,4)
gases and dust from emissions and to alter limestone, sand, and clay. 4. 01 Month
cement plants and prolong coal content in 4. Raw material storage yards and Production
inhalation of these gases combustion. coal yards must have a complete 5. 02 Weeks Manager (5)
and dust causes chronic steel roof.
respiratory and lung To collect dust, an 5. Dust-controlling bags in cooler
ailments such as Asthma electrostatic precipitator baghouses must be replaced with
and Lungs. Skin disorders is put exclusively on the new ones to boost infectious
are caused by fibrosis and Raw Mill. performance.
cement exposure.
On the clinker cooler, a
massive dust collection
(bag house) is erected.
Slips and trips can cause Housekeeping 1. Machines that become a source 1. 01 Month Manager
danger to workers, personnel are only of oil and lubricant leaks must be Mechanical
contractors, visitors and accessible in the fixed or replaced with new ones. 2. 01 Month (1)
interns. morning to clear 2. To avoid trailing wires, carefully
rubbish. arrange cables in the plant and build 3. 02 Weeks Manager
The plant's past records enough wiring and electrical outlets. Electrical (2)
reveal several accident The stairs have safety 3. All routes in the plant area must 4. 03 Weeks
reports caused by slips rails. be cleared of obstacles. Shift
and trips. Workers, for 4. Leaked oil and lubricant should 5. 05 days Supervisor
example, may be injured In certain offices, cables be cleaned as soon as possible by (3,4)
by tripping, sliding, or are correctly installed in having cleaning workers on duty
falling as a result of accordance with health throughout each shift. HSE
Learner name: Mazhar Ali Khan Page 5 of 17
 Hazard category and Who might be harmed What are you already What further controls/actions are Timescales for Responsible
hazard and how? doing? required? further actions person’s job
to be title
completed
(within …)
impediments, spilled oil, and safety regulations 5. Establish a regular evaluation Supervisor (5)
uneven terrain, and trailing to prevent slips and plan and teach appropriate staff on
wires, which can result in falls. proper housekeeping standards.
injuries, bone fractures, or
major head injuries that
can lead to coma or death.
6. Musculoskeletal Defective seats and All chairs and 1. All CCR operators' chairs must be 1. 01 Month Manager
& Upper limb incorrectly set equipment furnishings have replaced with new ones that have Admin (1,2)
disorders: might endanger CCR recently been examined adjustable armrests and sufficient 2. 02 Weeks
operators and process shift by the administrative lumbar support. Manager
Operators monitor and engineers. department. 2. Provide ergonomic tools like as 3. 05 days Production
manage the process in displays, keyboards, and CPUs that (3,5)
the Central manage Working on bad chairs for During each shift, one should be correctly set. 4. 03 Weeks
Room, although seats and an entire 8-hour shift may extra operator is 3. The CCR staff must be given HSE
certain equipment for cause musculoskeletal and assigned to give the adequate rest and breaks. 5. 01 Month Supervisor (4)
operators are upper-limb issues such as remaining 10 to 15 4. Educate employees on proper
malfunctioning or discomfort in the legs, minutes to all eight posture and ergonomics
improperly set, causing back, shoulder, head, and operators. approaches.
Musculoskeletal and neck, among other things. 5. Ensure CCR staff engagement in
Upper Limb problems. the development and
implementation of ergonomic
solutions.
7. Machinery & Workers, machine Only large machinery's 1. All machinery's belts, rollers, and 1. 01 Month Manager
Working Tools: operators, managers, and moving parts are blades must have safety shields Mechanical
visitors may be at risk. protected by safety fitted. 2. 01 Month (1)
Machines and equipment guards. 2. Install safety sensors on
can cause cuts, crushes, Improper machine machinery to reduce the likelihood 3. 01 Month Manager I&C
shears, and other injuries maintenance or the Visitors must have prior of an accident. (2)
due to poor use, design absence of safety approval. 3. Provide information from the 4. 03 Weeks
defects, insufficient measures surrounding manufacturer on the risks and safe Shift Engineer
maintenance, and a lack machinery can have Machine operators and practices for using each equipment 5. 01 Month (3)

Learner number: 00803531 Learner name: Mazhar Ali Khan Page 6 of 17

 Hazard category and
hazard
of training. Inadequate
training for personnel to
use these devices or
inadequate safety
precautions on these
machines.
Who might be harmed What are you already What further controls/actions are Timescales for Responsible
and how? doing? required? further actions person’s job
to be title
completed
(within …)
disastrous consequences workers are given safety in the local language as well as
for workers' health. helmets. English. 6. 02 Weeks Deputy
Vibration, noise, or sparks 4. A checklist should be established Manager
caused by incorrect and performed by experienced and Mechanical
maintenance or design skilled personnel once a month. (4)
defects can cause major 5. Workers should not be permitted
health difficulties, while the to wear loose dresses. HSE
absence of safety 6. Provide all essential PPE, such Supervisor (5)
measures might cause as safety shoes with metallic toes,
serious injuries. better-grip gloves, and safety Manager
helmets. Stores (6)

8. Fire:
The cement
manufacturing process at
MLCF includes high
temperatures maintained
by regulated coal burning,
but there is no fire
protection equipment in
place in the case of a
disaster.
Employees, contractors,
interns, tourists, firemen,
and severe damage to
machinery and structures
are all at risk.
In the event of a fire, the
lack of extinguishers, the
incorrect type of
extinguishers, or the
improper amount of
extinguishers can be
extremely dangerous
because fire cannot be
quelled in its early stages,
resulting in significant
damage to the health and
lives of workers, as well as
damage to machinery and
Only "class A fire" 1. Provide the factory with a fire 1. 01 Month Executive
extinguishers are given. engine (fire lorry/vehicle). Director (1)
2. Install a smoke and fire detection 2. 01 Month
Flammable objects are system. Manager I&C
kept in secure areas. 3. Every year, quarterly fire drills 3. 01 Month (2)
Fire drills are held once must be organized to put the system
a year. and workers' responses to the test. 4. 01 Month Manager HSE
4. Installation of fire hydrant system. (3,7)
5. A chart of evacuation and an 5. 03 Weeks
emergency exit must be installed. Manager
6. Post "No Smoking" signs 6. 02 Weeks Plant (4)
throughout the facility.
7. Provide firefighting training to all 7. 03 Weeks Manager
employees and repeat the training Admin (6)
procedure every year. 8. 05 Days
8. Provide proper personal Manager
protective equipment (PPE) to all Stores (8)
workers, including gloves, fire-
resistant clothing, helmets, and

Learner number: 00803531 Learner name: Mazhar Ali Khan Page 7 of 17

 Hazard category and
hazard
9. Vehicles
movement:
During my examination of
the cement loading area, I
noted that the tires, side
walls, and bed floor of a
few trucks were in poor
shape, and the roadways
within the plant grounds
were also damaged,
particularly near the
loading area.
10. Confined
Space:
The mechanical engineer
and his crew were
working inside the bag
filter since space was
restricted, the welding
operation produced
smoke, and ventilation
was inadequate.
Learner number: 00803531
Who might be harmed What are you already What further controls/actions are Timescales for Responsible
and how? doing? required? further actions person’s job
to be title
completed
(within …)
infrastructure. respirators.
All employees, The speed restriction in 1. Replace worn or damaged car 1. 01 Month Manager
administrative personnel, the factory premises tyres with new ones. Transport
drivers, contractors, and was 15 km/h for all 2. Repair the trucks' damaged body 2. 01 Month (1,2)
guests. vehicles. pieces.
3. Repair all of the road's broken 3. 03 Weeks Manager Civil
Vehicles can turn over The drivers were and uneven surfaces. Works (3,5,6)
because of poor tire experienced and had 4. Before use, all vehicles must go 4. 05 Days
condition, broken side the necessary through routine inspections. Supervisor
walls and bed floor, and certifications. 5. At the loading area, there should 5. 02 weeks Transport (4)
uneven road surfaces, be a well-designed, engineering-
resulting in fatalities and based parking lot. 6. 02 Weeks HSE
serious injuries. 6. Install speed restriction Supervisor (7)
signboards along roadsides. 7. 03 Weeks
7. Employees must be trained on
road safety.
Engineers, fabricators, Duties in the confined 1. Ventilation must be provided in all 1. 01 Week Manager
welders, and technicians space were given to tight locations. Plant (1)
were particularly experienced and 2. Before operating in restricted 2. 01 Month
vulnerable. physically fit staff. places, perform a gas test. Manager
3. Workers must be sufficiently 3. 03 Weeks Production (2)
Workers who were at Employees working in trained to operate in limited places.
danger of confined space tight places are 4. Ensure that first aid is available in 4. 05 Days HSE
risks might suffer from adequately supervised. tight spaces. Supervisor
physical entrapment, a 5. Workers in tight locations should 5. 03 weeks (3,4)
lack of oxygen, inhalation be given oral rehydration solutions.
of hazardous gasses, and Shift
exposure to combustible Supervisor (5)
materials, all of which can
result in major health
problems.
Learner name: Mazhar Ali Khan Page 8 of 17
 Hazard category and
hazard
11. Work at height:
A team of workers was
working at a height of 36
feet under the supervision
of a mechanical
supervisor, but the
scaffolding was wobbly
and dilapidated, and the
area under the "work at
height" sign was not
blocked.
12. Electricity:
Many electrical lines were
exposed or improperly
joined, as I discovered.
Trenches for
subterranean cables were
in poor condition, as were
cable trays. Substations
were not adequately
cooled.
Learner number: 00803531
Who might be harmed What are you already What further controls/actions are Timescales for Responsible
and how? doing? required? further actions person’s job
to be title
completed
(within …)
Fabricators, riggers, and Workers were required 1. Before beginning work, have a 1. 01 Week Shift
welders, among others, to wear full-body professional person check the Supervisor
may be injured when harness belts. scaffolding. 2. 03 Days (1,2,3)
operating at height. 2. Provide comprehensive edge
Supervisors and protection all the way around. 3. 04 Days HSE
The area around the workers were properly 3. Barricade work areas with Supervisor
workplace was not trained and fit to work at warning tape to prohibit movement 4. 05 Days (3,4,5,6)
barricaded, so any object heights. beneath or around scaffoldings.
that fell could hit someone 4. Worker fall prevention procedures 5. 03 weeks
passing by, or the shaky Workers were given must be put in place.
scaffolding could collapse, personal protective 5. A permit-to-work must be 6. 01 Week
resulting in fractures, head equipment (PPE). obtained before beginning work at
injuries, broken bones, height. 7. 01 Week
skull damage, brain 6. Maintain constant monitoring and
haemorrhages, back oversight.
injuries, spinal cord 7. "Work at Height" warning signs
injuries, collar bone must be posted.
injuries, nervous system
failure, disability, and even
death.
Workers, interns, The entrance to the 1. Replace the damaged wires with 1. 02 Weeks Manager
contractors, managers, subterranean trenches new ones. Electrical
visitors, and machine was barred. 2. Defective joints must be repaired 2. 02 Weeks (1,4)
operators are all included. appropriately.
Signage and warning 3. The electrical substation must be 3. 03 Weeks Electrical
Contact with live wires or signs were erected. maintained locked, and only Supervisor
exposed cables can result authorized workers are permitted 4. 05 Days (2,3,5)
in electrical shocks and The cable earthing is admission.
burns, which can result in done correctly. 4. Repairs are required for 5. 01 Day
lifelong disability or death. underground trenches and cable
Indirect contact, such as Personal protective trays.
Learner name: Mazhar Ali Khan Page 9 of 17
Hazard category and Who might be harmed What are you already What further controls/actions are Timescales for Responsible
hazard and how? doing? required? further actions person’s job
to be title
completed
(within …)
standing near faulty power equipment (PPE) was 5. All power wires must be
lines in the rain, can also given. inspected immediately.
cause electric shock.

Learner number: 00803531 Learner name: Mazhar Ali Khan Page 10 of 17

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

Moral, general legal and financial arguments for ALL actions

Moral, general legal and financial Moral Arguments:
arguments
It is the moral obligation of MLCF that its all workers must remain safe and healthy while
doing their tasks on the jobsite. Workers work hard to feed their family and to meet the
quarterly targets of MLCF, that’s why a safe working environment must be given to them, to
realise their jobs without danger of injury, illness, or death. It is also MLCF’s moral
responsibility to consider the worker's family members and the influence they have on the
workers after the accident, which will definitely assist them in completing his moral
responsibilities. Workplaces must be free of any risk of mental stress and strain, to boost
organizational efficiency. If a worker confronts with an accident, illness, or death, it affects
not just the worker but also their colleagues.
Legal Arguments:
This is the legal duty of cement plant to make sure the implementation of health and safety
measures in the organization. As ILO Convention No. 155 and Recommendation No.
164 require organizations to have health and safety measures at the workplace. The
cement plant follows the country laws like Pakistan Occupational Health and Safety Act
2018 being constituted by C155 and R164. If the organization is found with non-compliance
of laws and regulation will result in multiple penalties, fines and other legal objections.
Financial Arguments:
It is important to note down the organization losses due to an accident in the organization

Learner number: 00803531 Learner name: Mazhar Ali Khan Page 11 of 17


Justification for action 1
Action (Taken from column 4 of risk
assessment)
Specific legal arguments
Learner number: 00803531
while estimating finance and making the business profitable. The organization is paying
money to strengthen its health and safety culture.
Direct Financial losses:
Financial compensation to workers, sick pay given by the organization to the employees,
fines that the organization pay because of accident, the production loss and the repairs that
are done as a result of the accident refers to direct financial losses.
Indirect Financial losses:
the loss to organization's reputation, worker morale is reduced, Time that is wasted during
the investigation, and the expense to hire a new employee from the market are the indirect
financial losses
The maintenance of machines that are generating the intense vibrations need to be done
appropriately and timely (Hazard Category: Physical Hazard-vibrations)
As per the ILO convention of 1977 (C148, Article 9) which states that:
“As far as possible, the working environment shall be kept free from any hazard due to air pollution,
noise, or vibration-
By technical measures applied to new plant or processes in design or installation, or added to
existing plant or processes, or, where this is not possible.
By supplementary organisational measures.”
Whereas according to the R156 working environment (Air pollution, Noise and vibration
recommendation1977 (No. 156) says that: “Competent must be hired to ensure safe working
environment taking protection of health and equipment efficiency.”
As the suggested action was not being done which is the violation of laws and hence can be
resulted in the heavy penalty on the Maple Leaf Cement Factory.
Learner name: Mazhar Ali Khan Page 12 of 17
 Consideration of likelihood AND severity
 types of injury or ill health
 number of workers at risk
 how often the activity is carried
out
 how widespread the risk is
How effective the action is likely to be in
controlling the risk. This should include:
 the intended impact of the action;
 justification for the timescale that
you indicated in your risk
assessment; and
 whether you think the action will
Learner number: 00803531
The likelihood of getting vibration exposure from the conveyor machine is quite high as it is
creating the extreme level vibrations, and these machines are used regularly with the continuous
flow at working floor having too many vibrations.
I have categorised the severity level as:
➢ Low: Only first aid or minor medical treatment is required, and no damages occur.
➢ Moderate: Minor injury, admission to hospital and minor damage to machinery or building.
➢ Critical: Serious injury or health issues, disability lasting up to few months, admission in hospital,
significant damage to the machine, equipment and infrastructure.
➢ Catastrophic: Permanent/long-lasting disability, death, loss of infrastructure and machinery.
The severity of consequence is Critical as the conveyor machine produces a lot of extreme
vibrations.
 It may cause following injury or illness to health:
1. Headache
2. Physical Fatigue
3. Body numbness
4. Mental stress.
 Number of workers that are at risk are: 1 supervisor and 10 workers.
 The activity of conveyor machine is used on daily basis.
 The widespread the risk is mainly the packaging area and long belt conveyor from
crusher to reclaimer area where raw material is stocked and bags loading is carried
out at packing 24/7 respectively.
This action will be effective because timely maintenance and replacement of those machines and
equipment which are not working smoothly and causing excessive vibration.
 The intended impact of action will be great as of timely maintenance of conveyers
will not only assist to minimize vibrations but shall improve the productivity as well.
 The time scale assigned is 1.5 month, because it will require a lengthy procedure,
involving a complete inspection of all equipment to detect high vibration-producing
Learner name: Mazhar Ali Khan Page 13 of 17
 fully control the risk
Justification for action 2
Action (Taken from column 4 of risk
assessment)
Specific legal arguments
Consideration of likelihood AND severity
 types of injury or ill health
 number of workers at risk
 how often the activity is carried
out
 how widespread the risk is
Learner number: 00803531
machine parts and machine maintenance. Also, the budget for maintenance and
procurement of parts must be agreed by the finance manager and senior
management, as well as the time necessary for planning this activity.
 As the risk is significant, and the recommended measure would not completely
eliminate it, but it will help to lessen the risk associated with vibrations.
Installation of fire hydrant system. (Hazard Category-Fire)
To have firefighting systems measures, ILO Convention of C174 Prevention of major industrial
accidents convention 1993 article 9 (e) states that, “In order to any major industrial accident,
measure should be adopted to limit the consequences of major accidents”.
And as per ILO C155 Occupational safety and health Convention 1981 article 18 states
“Employer shall be required to provide, where necessary, for measure to deal with the emergencies
and accidents including first aid arrangements.”
As the suggested action was ignored and is the violation of laws and consequently can result in the
heavy penalty on the Maple Leaf Cement Factory.
The likelihood of getting harmed from the hazard category “fire” was high. As the possibility of
arising of fire event is high.
Just in case of any fire event, it can cause the great loss to the cement plant and severe risk injury
is there, burn or can cause death also, therefore the severity is Catastrophic as per severity
categorization given in “Justification for Action-1”
 Burns, smoke inhalation, CO poisoning, skin damage and PTSD, potentially fatal
depending on fire intensity,
 As burning at preheater and kiln is most crucial part of cement manufacturing,
number of workers at these areas is 30 at each shift.
 This activity is carried out for complete shift of 8-hour.
 The widespread the risk is present with the workers working in Preheater and Kiln
area are exposed to the risks of Fire.
Learner name: Mazhar Ali Khan Page 14 of 17
 How effective the action is likely to be in
controlling the risk. This should include:
 the intended impact of the action;
 justification for the timescale that
you indicated in your risk
assessment; and
 whether you think the action will
fully control the risk
Justification for action 3
Action (Taken from column 4 of risk
assessment)
Specific legal arguments
Consideration of likelihood AND severity
Learner number: 00803531
The action will be effective because installation of fire hydrant system in Preheater and Kiln areas
will minimize the risk associated with occurrence of event of uncontrollable fire outside Preheater
and Kiln.
 The intended impact of the action will be great for both workers and MLCF because
it will protect workers, eliminate manpower loss and save assets from negative
consequences.
 I have suggested a timeframe of 01 month for completion of activity because
approval from Executive Director will be required, then budget will be allocated and
in last a team for installation will be hired and then execution will be done.
 This measure will eliminate the risk of occurrence of fire event at workplace to great
extent and with the other advised action from the risk assessment will also be
necessary for complete risk control.
Installation of bag filter in Packing Area of Cement Plant. (Hazard Category: Hazardous
Substance)
The legal arguments that MLCF needs to implement should be, Article 13 (Operational Control) -
“ILO convention C170 Chemical Convention which states that “Employer shall make an
assessment of the risks arising from the use of chemicals at work, and shall protect workers against
such risks by appropriate means, such as: The choice of chemicals that eliminate or minimise the
risk The choice of technology that eliminate or minimise the risk The use of adequate engineering
control measures The adoption of working systems and practices that eliminate or minimise the
risk.”
While R177 – Chemicals Recommendation, 1990 (No. 177) article 11 (1)(a) states that “Where
workers are exposed to hazardous chemicals, the employer should be required to: (a) limit
exposure to such chemicals so as to protect the health of workers.”
The above suggested actions is not there at MLCF, workers are exposed to dust of cement that is
violation of laws that can result in penalties, and fines.
The likelihood of health issues due to exposure to hazardous substances is very high as workers
at packing plants inhale hazardous cement dust comprising silicon dioxide in the absence of a
ventilation system
Learner name: Mazhar Ali Khan Page 15 of 17
  types of injury or ill health
 number of workers at risk
 how often the activity is carried
out
 how widespread the risk is
The severity of consequence can be Catastrophic as per severity categorization is “ Justification
for Action-1”
 Following are the types of injury or ill health that can occur:
1. lungs disease like asthma, pneumoconiosis, and Lungs cancer that usually are the cause of
death.
2. Inhalation of cement dust having silica and prolong exposure leads to respiratory tract.
 There are 30 people including workers, operators of packers and supervisors in
each shift.
 Working with cement dust is daily activity of whole shift of 8 hours
 The widespread the risk is present with prolonged inhalation of cement dust in
packing area affects severe respiratory complications due to epithelial damage.

How effective the action is likely to be in

The action will be effective because installation of bag filter in packing area will minimize the risk
controlling the risk. This should include:
associated with exposure to cement dust having particles of silica and exclude the negative effects.
 the intended impact of the action;
 The intended impact of the action will be good for employees as it will safeguard
 justification for the timescale that
you indicated in your risk workers and save assets from negative effects.
assessment; and  I have recommended a timescale of 01 month for completion of activity as approval
 whether you think the action will from the Executive Director will be needed, and team for installation will be hired to
fully control the risk do the job.
 As the risk is too high and the proposed action will decrease it to the minimum level,
and other advised action from the risk assessment will be necessary too, for
completion of risk control.

Part 4: Review, communicate and check

Suggested word counts for each section:
 Planned review date or period and reasoning for this: 50 - 100 words
 How the risk assessment findings will be communicated and who needs to know the information: 100 - 150 words
 Follow up on the risk assessment: 100 - 150 words.
Planned review date/period with As of now, I planned to review my risk assessment after a year and the date of 11th December,
reasoning 2024 is planned for the review of my risk assessment since MLCF has the policy of reviewing risk

Learner number: 00803531 Learner name: Mazhar Ali Khan Page 16 of 17


How the risk assessment findings will be
communicated AND who you need to tell
How you will follow up on the risk
assessment to check that the actions
have been carried out
Learner number: 00803531
assessment one time a year, whereas article 7 of C155 also highlights on the review at proper
intervals when it comes to health and safety. Although if any unexpected incident happens,
management changes or legal procedure changes, then MLCF Plant team will have to review the
risk assessment earlier than mentioned date.
Before concluding the draft of my risk assessment, a formal meeting will be arranged with Plant
Manager and HSE personnel to communicate all the findings of my risk assessment in an
understandable way whilst meeting of minutes will be recorded accordingly. After that the finalized
draft will be shared with the Managing Director (MD) for final approval. after receiving approval from
MD, the risk assessment will be communicated to the HSE Manager and HSE supervisors. And an
overview of the risk assessment will be announced on notice boards to share with all workers and
also toolbox talk will be arranged with all workers of plants at their respective departments.
To follow up my risk assessment, I have saved the contacts of all responsible persons in my phone
and also in my diary. I have also shared my contact details with these personnel along with the risk
assessment findings. Furthermore, I will communicate each responsible person within the given
time frame to take report on suggested control measure. If the performance would not satisfy me,
then I will search out the reason behind delay. I will speak to Executive Director and then Managing
Director and request them to resolve the issues causing delay. Such follow up will safeguard the
MLCF from moral, legal and financial consequences and will raise the organisation repute that will
subsequently benefits the organisation with all aspects.
Learner name: Mazhar Ali Khan Page 17 of 17