Risk assessment Report for Omar Jibran

engineering Ltd

NAME OF ASSESOR : MUAHAMMAD ASAD AWAN

AREA OF INSPECTION :
Rim plant (press shop& welding line), fender (press shop & spot welding line) , Fuel tank (press
shop and welding line) ,Electroplating plant (Manual Auto), Injection Molding, Maintenance
shop, Die shop, Shearing shop ,Store &shipping ,packing area ,polishing shop ,scrap area
,welfare facilities
DATE OF INSPECTION:
January 6, 2020 to January 16, 2020
 RISK MATRIX
4 3 2 1
LIKELIHOOD

VERY LIKELY UNLIKELY HIGHLY

LIKELY UNLIKELY
STOP THE WORK IMMEDIATELEY(8-16)
HIGH 16 HIGH 12 HIGH 8 MEDIUM 4
CONTINUE BUT IMPLEMENT ADDITIONAL
4
CONTROL(3-6) FATALITY
CONTINUE BUT RIVIEW PEROIDICALLY TO ENSURE
CONTROL REMAIN EFFECTIVE (1-2) HIGH 12 HIGH 9 MEDIUM 6 MEDIUM 3

3
MAJOR
INJURIES

CONSEQUENCES
HIGH 8 MEDIUM 6 MEDIUM 4 LOW 2
2
MINOR
INJURIES

1 MEDIUM 4 MEDIUM 3 LOW 2 LOW 1

NEGLIGIBLE
INJURIES
 Risk Assessment Sheet For Rim Plant(Omar Jibran engineering)
Problem
No fence around coil loading
1 machine
Worker working on
2 Seam&butt welding machine
without wearing adequate
PPE’s using grinder without
gloves and safety glasses to
clean disc at seam welding
machine
There is no guard install on the
3 machine While doing grinding
and polishing rims manually
and it is observed workers are
not using PPE’s
Lose electrical connection and
4 open circuit board
6 January 2020
Observation/Consequences Counter Measures Required Risk
which may cause an injury in case of collision to Workers passing by install fence around if needed
&the operators working on the machine LOW
any particle coming out of the machine while using grinder can enforce worker to use PPE’s&
damage the eyes and cause injury training of worker
MEDIUM
It could be resulted an injury in case of disk break and contact Install guard around the
with grinding disc or polishing belt ,operators are also expose grinding and polishing
to metal dust which could lead to respiratory problem machines& and make sure MEDIUM
workers are using PPE’s,(mask)
job rotation must take into
consideration
Loose electrical connection and open circuit board can cause Circuit board should be closed
accidents if touched by mistake properly and only opened by
authorized person when need
loose connections must be High
eliminate and provide proper
socket
 Unorganized inventory at butt welding Unorganized inventory can cause blockage of Inventory must be placed and
5 ,seam welding and grinding area walking area and can increase the risk in case of stacked properly
any emergency LOW

There is a absence of first aid box at rim Absence of first aid can cause serious damage to Provide first aid box as per requirement
pant the health of injured or ill person because some
6 types of accident requires urgent medical
attention MEDIUM
Ill placed material Open electrical panel Oil spillage Poor house keeping

Material on Edible inside air

walkways cooler

Risk Assessment Sheet For Fender (press shop &spot welding line)
Problem
It was observed by me most of the
1 press machine operators are
operating machines without
wearing safety helmet
Very poor housekeeping all around
2 the fender shop the remaining
piece of metal with sharp edges
(scrap)after drawing, trimming
,edge ,and side cutting thrown on
the floor most of the time and there
is oil spillage around most of press
shop
At spot welding line worker are
3 manually operated the machine
through pedal for contraction of
electrodes there is twisted wires
around the pedal
Spot welding machine operator are
4 operating the machine without
wearing masks and safety glasses
any sparks while doing the welding
can cause the injury
Observation
/Consequences
It could cause head injury in case of
collision with machine
which could cause slip trip and
resulted an injury to worker
it can be the reason of tripping and
could cause injury top worker
it could cause skin burn and damage to Enforce and train workers to use personal
eyes
7 January 2020
Counter Measures Required Risk
Provide safety helmet and instruct operators
not to lean inside the machine while working
HIGH
Provide more personal to take out filled scrap
box and brought empty one as per need
,instruct housekeeper to clean the oil spillage in
walkways as it happened and instruct workers
not over filled the scrap box MEDIUM
Clean the area around pedal before using it and
make sure there is no spare things around pedal
MEDIUM
protective equipment
MEDIUM
6 Untrained cleaner Cleaning under the draw
machine in confined space without full filling any
Prerequisites while draw machine is working
7 twisted wires around the pedal of spot welding
machines
Workers are not wearing gloves while using hand
8 tools(grinder) to grind the sharp edges and
cleaning the hot electrodes of spot machine
Most of the workers working in fender shop are
9 changing clothes inside the fender shop and
keeping it there near electric cables
It could be very dangerous and
lead to serious accident in case of
any emergency due oxygen
deficiency or oil spillage
could disturb operator feet and
cause injury to the foot due to fall
or collision with electrodes
Electrodes could burn the skin and hand
could be injured with sharp edges
it could be the reason to ignite fire in
case of damaged electric cable or lose
connection
Training regarding confined
space entry and cleansing
Implement PTW system HIGH
And ensure only trained
worker enter in the confined
space
Make sure to place around the
pedal is clean and without any
hurdle LOW
Shift supervisor must ensure
workers are using proper PPE,s
while working LOW
Provide changing area
&and make sure no one is
changing clothes inside fender MEDIUM
shop
 Material placed
on floor around
working area

Scrap placed on Workers changes and keep clothes

floor inside shop

Open electrical Electrical cables Fire

panel and cables are not insulated extinguisher
are not fastened properly are not at
securely designated
place

Scrap thrown
behind machines
 Risk Assessment Sheet For Electroplating Plant (Omar Jibran engineering) 8 January 2020

Problem Observation/Consequences Counter Measures Required Risk

1 Faded walkways and At manual electroplating plant walkways are very narrowed or Must provide storage area
absence of walkways not available and there is not enough storage available for and it should be separated
no marking for placing raw material or spare jigs . This can be the reason for from walkways &walkways
storage and placing accident or lost to material and could be catastrophic in case must be kept clear &clean all LOW
new raw material of fire the time

2 most of the times This can be the reason of foot injury due to the slip (nature of Provide safety shoes /long
safety shoes(long job and hazard present in this job) boots and strictly assured
boots) are missing their use at plant HIGH

3 most of the workers It can damage the skin due to contact with chemicals Provide plastic gloves to all
are not wearing the workers at electroplating
plastic gloves plant HIGH

4 open electric panels It can cause fire or injury to the workers in case of any contact Electrical panels must be MEDIUM
found all around the covered and closed
place

5 Improper wiring, Loose electrical connection and dangerously install circuit Electric wire must be placed
loose electrical breaker can cause fire or electric shock to the workers working at right place and properly
connections& around insulated HIGH
dangerously placed
circuit breakers

6 Operators are expose Skin allergy breathing problem and itching in eyes can be Adequate clothing and LOW
to chemical fumes, caused by chemical fumes shower area and anti allergic
mist and vapors medicine must be provided
7 Loose live Gas pipes of oxy-
fuel welding passing near the
fire which use to light up the
welding torch
8 Housekeeping &workers
changing and putting clothes
inside the plant near the live
loose electric cables
9 Open chemicals containers
without MSDS display on it
10 There is not enough fire
extinguisher at electroplating
plant
11 Faulty and unused
transformers are all around
the manual electroplating
plants
any contact of live gas pipe with fire can cause a very gas pipes must be placed at HIGH
serious accident and could damaged plant and injure the right placed and properly
personal insulated
Used gloves ,mask and bottle caps are found on the floor Provide bins to throw Used MEDIUM
which could block the drainage& and junk
material and ensure no one
throws anything else where
but in the bin
Waste of material and could be the reason of accident in Chemical should be placed MEDIUM
case of spillage properly and closed with MSDS
display on it
It could be catastrophic in case of fire if there is not Provide fire extinguishers per HIGH
enough availability of fire extinguisher because fire need and their use
extinguisher can save lives and property by containing a
small fire until fire department arrives
It could he the hurdle in case of emergency for the safe
exit of workers
Chemical containers are placed on floor NOT USING PPE’s
POOR HOUSE Jig CARRIER
and there is no MSDS displayed on it
KEEPING PLACED ON FLOOR

Conveyers belt Empty trolleys on

Material placed
hooks are very low exit route
on walkways
right behind work which block the
station stairs

Unused
transformers placed
inside nickel plant Spillage all around
the nickel plant
 Poor house
Used PPEs thrown keeping
under nickel tanks
Clothes inside
plant

Unused Chemicals Scrap and garbage

placed on work thrown inside old
station tanks

Open electrical Hand tool

panels placed
dangerously on
walkways

Oil spillage around

Pointing jigs placed
oven work station
dangerously placed
Lose electrical
behind the workers
connection
Open electrical panel Workers clothes Jigs placed on
and damaged cables inside plant walkways
 Risk Assessment Sheet For Packing department(Omar Jibran engineering) 9 January 2020

Problem Observation/Consequences Counter Measures Required Risk

1 No safety shoes Working wearing causal shoes this can cause severe Safety use must be provided and
injury in case of contact with edges supervisor must ensure their use
MEDIUM

2 No/faded walkways. No Faded or no walkways can cause confusion for Walkways must be marked and storage
marking for storage area walking area and storage space. This can cause area must be provided separately
accident in ignorance MEDIUM

3 Not enough fire extinguisher in There is only one fire extinguisher in packing shop, to More CO2 fire extinguisher must be
packing area contain fire can be difficult due to the nature of work provided
at packing shop HIGH

4 Conjusted Place At packing area there is very little space available to Provide more space
store material and work simultaneously it can be the
reason of accident if there is a pressure of order LOW
completion
 Working on walkways
Not provided proper Electrical panel are not instead of their work
containers for garbage accessible station

Maintenance job at
height without fall
protection and PPE’s

Housekeepers are not

Empty trolleys on collecting garbage
walkways instead of timely
their designated place
 Risk Assessment Sheet For Fuel Tank production (Omar Jibran engineering) 10 January 2020

Problem Observation/Consequences Counter Measures Required Risk

1 No designated place for raw Metal sheets for draw press placed on the floor can There should be designated
material be the reason of accident and can increase the place for metal sheet and must
likelihood of incident in case of emergency ensure not to place raw material MEDIUM
on walkways

2 Without safety helmet and gloves It was observed that operators are not wearing safety Provide safety
helmet in press shop which could be resulted a injury
in case of collision with draw machine during its MEDIUM
operation

3 Oil spills Oil spills around the draw machine can cause slippage Oil spills must be control and
and resulted an injury clean if happened during
machine operations or LOW
maintenance activity

4 Repairing activity at height without
any fall protection
Maintenance workers are repairing the machine at Training of workers
height without wearing any PPE’s and fall protection Use safety harness while
which could resulted head injury or death in case of working at height HIGH
fall from height Use PERSONAL PROTECTAIVE
UNIT
5 No safety shoes Workers are not wearing safety shoes at press Provide safety shoes
shop which could be reason of injury because And must ensure their use
there is scrap pieces all around the press shop MEDIUM
with sharp edges

Operative was carrying out grinding It could lead to injury like cut and abrasion Informed supervisor to provide
and cutting works without wearing adequate PPE apron ,face
6 proper PPE’s i.e. Apron &Face Shield shield and ensure their use MEDIUM

7 During inspection it was found that It could be the reason of fire expansion in case Provide changing area and
most of the press shop workers of any short circuit and cause loss of lives and ensure no one changes clothes
changing clothes inside the FT shop equipment inside the plant HIGH
and keeping it there

8 Operators are working in Excessive Press machines due to worn-out parts and Provide ear muffs and ear
noise and vibration without PPE’s pneumatic is creating high level noise which plugs
can cause noise-induced deafness Job rotation LOW

9 Open electrical panel Electrical panel are left open and worker are Electrical panel should b closed
working beside it any contact with live parts can and locked and only use and
cause shock ,burns and death open by authorized person HIGH
 Doing
grinding
without
Material placed using
on walkways platform

Electrical Hook of
equipment placed conveyer belt Carton for
near Lose installed very packing is placed
electrical low on wet floor
connection

Open electrical
panel near
quality desk
Maintenance of
machine on height
without fall
protection
 Risk Assessment Sheet For Injection Molding(Omar Jibran engineering) 11 January 2020

Problem Observation/Consequences Counter Measures Required Risk

1 Chemical hazard During operations Mold release spray can inhale by Provide adequate face mask
workers due to absence of proper respiratory mask and their use must be
and can cause health issues like suffocation shortness ensured MEDIUM
of breath

2 Live Electrical cables Live electrical cable is hanging around the molding Electrical connection must be
machine any contact with cable can cause shock burn installed safely and properly
and death to a person insulated LOW

3 Dangerously placed inventory Dangerously placed unorganized Inventory stack. Stacking must be managed
stock Inventory stack reaching up to 7 meter placed on and placed in designated
walkways and unorganized can cause accidents in place without any delay LOW
case of fall and could be reason loss of material and
human lives

4 Oil spills all around the place It was observed there is oil spillage around the Clean the floor after
molding shop mainly due to the maintenance of mold maintenance activity and
,oil spill can cause slippage and could be the reason provide de MEDIUM
of accident
5 Dangerously placed mold
6 Dangerously placed electrical connection
7 Crane Operator
8 Non conformance with PPE’s
Molds stacking is extremely
dangerous and done on a
uneven floor. This can cause
misbalancing resulting in
falling of molds which can be
extremely dangerous. And
could be resulted loss of
equipment and lives of human
Hanging Electrical cables and
unsafe electrical connections.
Hanging electrical cables can
cause serious accidents and
can result in huge loss. And
unsafe electrical connections
can damage equipment and
cause fire
No specific path provided for
crane operator. Crane
operator can trip or fall and
crane can get out of control.
It was observed most of the
workers are not using PPE’s
while doing dangerous jobs it
could be resulted an injury
Separate area must be
provided with fence around to
stacked mold
LOW
Electrical cables should be
isolated properly and
connection must be done
safely.
MEDIUM
Specific and designated path
must be provided for operator
to use crane safely MEDIUM
Supervisor must ensure the
use of PPE’s and provide MEDIUM
training regarding safe
method of work
 Scrap and empty
bags thrown
Garbage thrown
outside instead of
Open electrical under the
trash can and Carrying equipment
panels crusher
containers manually

Empty bags of
used material kept
Unused metal Poorly under the molding
Oil spillage
sheets on floor maintained machine
mold
 no designated path for
operator to using crane
safely

Inventory stack
exceeding 7 meter Lifting heavy load
height and not properly without using helmet
secured
 Risk Assessment Sheet For Die& Maintenance shop (Omar Jibran engineering)

Problem Observation/Consequences Counter Measures Required Risk

4
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