HealthSafety
UK health and safety management for MNMUK manufacturing operations, aligned with the Health and Safety at Work Act 1974, UK HSE regulations, and IATF 16949.
Workflow Routing
| Workflow | Trigger | File |
|---|
| RiskAssessment | "risk assessment", "hazard assessment" | Workflows/RiskAssessment.md |
| IncidentReporting | "accident", "incident", "near miss" | Workflows/IncidentReporting.md |
| CoshhAssessment | "COSHH", "chemical", "hazardous substance" | Workflows/CoshhAssessment.md |
| SafetyAudit | "safety audit", "inspection" | Workflows/SafetyAudit.md |
Legal Framework (UK)
Primary Legislation
| Act/Regulation | Requirement | MNMUK Application |
|---|
| Health and Safety at Work Act 1974 | General duty of care | Foundation of all H&S |
| Management of Health and Safety at Work Regulations 1999 | Risk assessment, competent persons | Risk assessment programme |
| COSHH Regulations 2002 | Control of hazardous substances | Chemical management |
| PUWER 1998 | Provision and use of work equipment | Machine safety |
| Manual Handling Operations Regulations 1992 | Reduce manual handling risks | Lifting assessments |
| PPE at Work Regulations 1992 | Provide appropriate PPE | PPE programme |
| RIDDOR 2013 | Report specified injuries/incidents | Incident reporting |
Enforcement
| Body | Role |
|---|
| Health and Safety Executive (HSE) | Primary enforcement authority |
| Local Authority | Certain workplace types |
| Environment Agency | Environmental hazards |
IATF 16949 Alignment
| IATF Clause | Requirement | H&S Coverage |
|---|
| 7.1.4 | Environment for operation | Physical, psychological, social factors |
| 7.1.4.1 | Cleanliness of premises | Housekeeping, 5S, safety |
| 8.5.1.5 | Total productive maintenance | Equipment safety maintenance |
| 7.2 | Competence | H&S training requirements |
Reference: ~/projects/work/docs/work-instructions/procedures/hr/HRP-004_Health_Safety.md
Risk Assessment Framework
UK HSE 5-Step Methodology
All risk assessments at MNMUK must follow the UK HSE 5-step methodology:
| Step | HSE Step | Description |
|---|
| 1 | Identify the hazards | Walk the area, consult workers, review SDS/accident history, consider non-routine tasks |
| 2 | Decide who might be harmed and how | Employees, contractors, visitors, vulnerable persons; identify exposure routes |
| 3 | Evaluate the risks and decide on precautions | Consider existing controls, apply hierarchy of control, use risk matrix to prioritise |
| 4 | Record your findings and implement them | Document hazards, persons at risk, existing and additional controls; assign actions with owners and dates |
| 5 | Review your assessment and update if necessary | Review after incidents, process changes, or at least annually |
Hazard Categories
| Category | Examples | Assessment Approach |
|---|
| Mechanical | Moving parts, nip points, ejection | Machine-specific assessment |
| Chemical | Coolants, solvents, oils | COSHH assessment |
| Physical | Noise, vibration, temperature | Environmental monitoring |
| Ergonomic | Repetitive motion, posture, lifting | Workstation assessment |
| Electrical | Shock, arc flash | Electrical safety programme |
Risk Matrix (Step 3)
PPE Requirements
PPE by Area
| Area | Minimum PPE | Additional as Required |
|---|
| Manufacturing floor | Safety glasses, safety footwear | Hearing protection |
| Machine operation | + Hearing protection | Face shield for grinding |
| Chemical handling | + Chemical-resistant gloves | Face shield, apron |
| Welding areas | Welding helmet, leather gloves | Fire-resistant clothing |
| Overhead work | Hard hat | Fall protection |
PPE Management
| Requirement | Frequency |
|---|
| Issue and record | At hire / as needed |
| Condition inspection | Daily by user |
| Replacement | When damaged or worn |
| Training on use | At issue |
Machine Safety
Key Requirements (PUWER)
| Requirement | Standard |
|---|
| Guarding | All nip points, moving parts guarded |
| Interlocks | Guards interlocked where practical |
| Emergency stops | Accessible within reach |
| Maintenance | Safe systems, isolation |
Lockout/Tagout (LOTO)
8-Step LOTO Procedure:
- Notify - Inform affected employees
- Identify - Identify all energy sources
- Isolate - Shut down equipment normally
- Lock/Tag - Apply personal lock and tag
- Release - Release stored energy
- Verify - Attempt start to confirm isolation
- Perform - Complete maintenance work
- Restore - Remove locks/tags, restore energy
Energy Types:
- Electrical
- Pneumatic
- Hydraulic
- Mechanical (springs, gravity)
- Thermal
- Chemical
COSHH Management
Hazardous Substances at MNMUK
| Category | Examples | Controls |
|---|
| Cutting fluids | Coolants, neat oils | LEV, PPE, skin care |
| Cleaning solvents | Degreasers, IPA | Ventilation, PPE |
| Lubricants | Oils, greases | Skin protection |
| Welding fumes | Metal fumes | LEV, respiratory protection |
COSHH Requirements
| Requirement | Action |
|---|
| Assessment | For each substance/process |
| Control measures | Hierarchy of controls |
| Health surveillance | Where required by assessment |
| Information/training | All exposed employees |
| SDS availability | At point of use |
Manual Handling
Assessment Triggers
| Factor | Assessment Required |
|---|
| Weight | >10kg regular handling |
| Frequency | Repeated lifting |
| Posture | Twisting, bending, reaching |
| Environment | Space constraints |
| Individual | Known conditions |
Control Hierarchy
- Eliminate - Remove need for manual handling
- Mechanise - Hoists, trolleys, conveyors
- Reduce - Lighter loads, team lifting
- Train - Proper technique
Incident Management
Reportable Incidents (RIDDOR)
| Category | Examples | Reporting |
|---|
| Fatal | Any workplace death | Immediate |
| Specified injuries | Fractures, amputations, loss of sight | Within 10 days |
| Over 7-day incapacitation | Unable to work >7 days | Within 15 days |
| Occupational diseases | As specified in RIDDOR | When diagnosed |
| Dangerous occurrences | Near misses as specified | Within 10 days |
Investigation Process
- Immediate - Secure scene, care for injured
- Report - Complete incident form
- Investigate - Gather facts, interview witnesses
- Root cause - 5 Whys, fishbone analysis
- Actions - Corrective and preventive
- Close - Verify effectiveness
Emergency Procedures
Emergency Types
| Emergency | Response |
|---|
| Fire | Alarm, evacuate, assemble, account |
| Medical | First aid, call 999, assist responders |
| Chemical spill | Evacuate area, contain if safe, notify |
| Gas leak | Evacuate, no ignition sources, notify |
Emergency Equipment
| Equipment | Location | Inspection |
|---|
| Fire extinguishers | Throughout facility | Monthly visual, annual service |
| First aid kits | Each department | Monthly check |
| AED | Main entrance, production | Monthly check |
| Eye wash stations | Chemical areas | Weekly flush |
| Spill kits | Chemical storage, machines | Monthly check |
Drill Schedule
| Drill | Frequency |
|---|
| Fire evacuation | Quarterly |
| First aid response | Annual |
| Chemical spill | Annual |
Safety Training
Training Matrix
| Training | Who | When | Refresher |
|---|
| General safety induction | All employees | At hire | Annual |
| Job-specific hazards | Affected employees | At assignment | As needed |
| PPE use | All employees | At hire/issue | As needed |
| LOTO | Authorized personnel | Initial | Annual |
| First aid | Designated responders | Initial | Biennial |
| Fire warden | Designated wardens | Initial | Annual |
| Forklift/MHE | Operators | Initial | Triennial |
| COSHH | Exposed employees | At assignment | Annual |
Safety Audits
Audit Programme
| Audit Type | Frequency | Scope |
|---|
| Department inspection | Weekly | Area-specific hazards |
| Safety committee | Monthly | Rotating areas |
| Management review | Quarterly | Programme effectiveness |
| External audit | Annual | Full compliance |
Audit Focus Areas
- Housekeeping and 5S
- PPE compliance
- Machine guarding
- Chemical storage
- Emergency equipment
- Documentation currency
Performance Metrics
| Metric | Target | Frequency |
|---|
| Recordable incident rate | <2.0 | Monthly |
| Lost time incident rate | <1.0 | Monthly |
| Near miss reports | >5/month | Monthly |
| Training completion | 100% | Monthly |
| Audit score | >90% | Monthly |
| Open actions | <5 overdue | Weekly |
Record Retention
| Record | Retention Period |
|---|
| Risk assessments | 3 years (or while valid) |
| Training records | Employment + 7 years |
| Incident reports | 10 years |
| RIDDOR reports | 10 years |
| COSHH assessments | 40 years |
| Health surveillance | 40 years |
| Audit records | 3 years |
Integration with Other Skills
| Skill | Integration Point |
|---|
| AutomotiveManufacturing | Process safety in procedures |
| Pfmea | Safety failure modes |
| Assemblyoperations | Assembly-specific hazards |
| Maintenancepm | Equipment safety checks |
| Tribalknowledge | Safety practices capture |
Examples
Example 1: New machine installation
User: "We're installing a new CNC lathe"
→ Conduct risk assessment (Workflows/RiskAssessment.md)
→ Verify guarding per PUWER
→ Develop LOTO procedure
→ Train operators
→ Update department risk assessment
Example 2: Chemical spill incident
User: "We had a coolant spill in Machine Shop"
→ Ensure immediate response complete
→ Complete incident report (Workflows/IncidentReporting.md)
→ Investigate root cause
→ Review COSHH assessment
→ Implement corrective actions
Example 3: New substance introduction
User: "We want to use a new degreaser"
→ Obtain SDS from supplier
→ Conduct COSHH assessment (Workflows/CoshhAssessment.md)
→ Determine controls required
→ Train affected employees
→ Update chemical register
