Manager Responsible for H&S

Risk Assessment Template(Quantified)

Manager responsible for H&S: / Dave Grimwood / Location: / Building 99 Workshops / Date of assessment: / 16th December 2015
Name(s) of risk assessor(s): / Mary Cannon (MC); Dave Pearce (DP) (plant maintenance supervisor and health and safety representative); Dave Brundell (DB) (group leader) John Massie (Quality Compliance Manager) / Generic assessment?1 / Yes / No* (*delete)
Brief description of work place and work activities: / Review frequency2: / Yearly
This risk assessment covers the work activities carried out by plant maintenance personnel. Plant maintenance provides a support service for aircraft maintenance. There is very little building maintenance work as most of this is sub-contracted. Most of the tasks described are carried out in Building 99 workshop. Some are performed in H61. Portable tools can be used in most areas although the tendency is to always carry out the task in the workshop whenever possible.
Three engineers work full time in the workshop. Working hours are typically between 7.00 a.m. and 3.00 p.m. Monday to Friday. These engineers have various engineering qualifications and have attended a range of training courses. They have a combined experience of over 65 years.Occasionally contractors work on the premises particularly to carry out maintenance of vehicles. These activities are outside the scope of this assessment. However, as no risk assessments or method statements are available for contractor activities a corrective action has been noted.
This risk assessment does not cover the Supply chain area of B99. This is covered separately by the Supply chain B100/99/B100A risk assessment
This assessment takes account of the requirements of the Management of Health and Safety at Work Regulations 1999 and the Provision and Use of Work Equipment Regulations 1998.To facilitate the identification of hazard and risk assessment, the following have taken place:
-Discussions between the aforementioned
-Observation and demonstration of operation of machinery
-Walk-through of Building 99
-Accident reports
-A review of some of the frontline maintenance work order
-Training records
-A review of manufacturers’ instructions/information where available (it is important to note that many of the machines are very old and no longer have manufactures instruction booklets, neither is anything available on the internet)
-A review of literature from the British Compressed Gases Association
-A review of HSE guidance documents:
-HSG 129 Health and safety in engineering workshops
-HSG 17 Safety in the use of abrasive wheels
-HSE 8 Take care with oxygen
-HSG 139 Safe use of compressed gas in welding, flame cutting and allied process
-WIS16 Circular saw benches – Safe working practices
-WIS36 Safe use of manually operated cross-cut sawing machines
NOTE: This assessment does not include the COSHH assessments, which are available on SYPOL unless where a hazardous substances is identified for which there is no COSHH assessment.
Key for who is affected?:
E = Engineer; C = Contractor, V = visitor, TP = third parties e.g. delivery drivers
Risk / Action Plan / Residual Risk
Number / Describe the tasks / What are the hazards? / Who is affected? / Current / existing control measures / Severity (S) / Likelihood (L) / Risk rating (R) / Action plan to reduce risk further3 / Action owner? / Action due date? / Severity (S) / Likelihood (L) / Risk rating (R) / Monitoring
1 / Generic:
This includes assessment of generic hazards which apply across many of the tasks detailed below such as unauthorised access, manual handling and defective equipment to avoid repetition. / Inadequate emergency response to accidents resulting in injury and incidents including fire and spillages e.g. of fuel, oils, grease and paint.
Poor lighting
Poor housekeeping
Unauthorised access to premises and unauthorised use of the work equipment by untrained personnel.
Restricted access/space around workshop and machinery.
Defective portable electrical equipment e.g. damaged cables, plug cord grips or plugs, overheating, fixed electrical equipmentor electrical installations.
Exposure to microwaves.
Manual handling of heavy, bulky, awkward items of various shapes and sizes.
Excessive noise exposure
Excessive vibration exposure
Exposure to hazardous substances.
Poor personnel hygiene
Smoking
Inadequate training.
Residual risk not adequately controlled / E, C, V, TP / First aid provisions
-First aid kit
-Burns kit
-Eye wash bottles
-First aiders
-Plasters dispensers
Spill kit available
Fire risk assessment completed for the premises.All actions/ recommendations complete
Maintenance and servicing of fire extinguishers
Fire call points, alarms, emergency lighting, directional signs, portable extinguishers and fire blankets installed and maintained.
Fire procedures implemented.
PAT testing schedule
Portable RCD (extension lead) with portable tools if no RCD integral with socket
Fire awareness training for all personnel.
Appointed fire warden trained.
Good lighting throughout workplace and task specific lighting available as specified.
Workplace housekeeping standards are good throughout.
Periodic workplace H&S inspections.
Plant maintenance coordinator and DB are IOSH managing safely trained.
Noise level reviewed
Secure premises compound with controlled vehicle and pedestrian access gates. Workshops locked when engineers absent.
Adequate access and space around all machinery and equipment.
Portable appliance testing (PAT) carried out periodically on portable appliances by competently personnel trained to the In-Service Inspection and Testing of Electrical Equipment (City and Guilds 2377-22 ).
Electrical safety check carried out on hardwired electrical equipment.
Fixed electrical testing carried out May 2011. Due May 2016.
SYPOL training
Use RCD socket outlets where available.
Leak test carried out on microwave annually.
Manual handling training.
Manual handling aids such as
-Pedestrian pallet stacker
-Trolleys
PPE storage cabinet in place
PPE issued using ID swipe card
Health surveillance by Occupational Health Service Provider carried out occupational health role profile and will be repeated at statutory intervals where the risk exists:
-Audiometry
-Hand arm vibration
-Skin checks
-Lung function
-Work at height
-Fork lift truck
No adverse results have been identified from any of the above surveillance.
MSDS and COSHH assessments available on SYPOL.
Face fit testing carried out by competent personnel.
Workshop has good standard of general ventilation
Wash facilities with skin safety centres provided.
Personnel wear protective overalls.
Smoking prohibited on premises except at the designated smoking area which is away from the workshop and yard.
AMOS controls training records (albeit some records are not on AMOS)
Safety footwear worn throughout workshop.
Visitors are escorted.
Induction programme for new starters.
PPE is to required standards as documented on PPE assessment.
User manuals and log books prepared f LEV systems (refer to LEV report to comply with Health and Safety Guidance note 258 and section 9 therein. / 3 / 2 / 6 / Wherever possible when portable tools are replaced, 110 V tools should be procured.
Vibration Risk assessments
For individual equipment required following vibration survey
Carry out air monitoring to establish the levels (if any) of hazardous substance exposure. / DB/MC
P Jarvis MC / May 15
May 15
complete / 3 / 1 / 3 / Angle grinder replaced to 110v
Complete
2 / Storage of gas cylinders at building 99
-Oxygen
-Nitrogen
-Acetylene
-Propane
-Argon
Storage of gas bottles outside line office H61:
-Oxygen
-Nitrogen
-Propane
Delivery of gas bottles to B99 by supplier.
Carriage of gas bottles between B99 and H61 in transit van (maximum three cylinders).
Installation of nitrogen and oxygen on to rigs in H61.
Installation of oxygen and acetylene on to rig in B99.
Installation of argon on the MIG rig in B99.
Manual handling of gas bottles. / Manual handling of gas cylinders which can be heavy and unstable due to base to height ratio.
Being struck or crushed by falling gas cylinders.
Dieseling: Oil and grease contamination of oxygen components leading to fire and explosion.
Explosion due to oxygen enriched atmospheres.
Cold burns due to excessive cold cylinder surfaces in cold/wet weather conditions.
Highly flammable gases (propane) and Oxygen stored in close proximity.
Combustible materials stored nearby.
Adjacent premises: Social club purpose built barbeque located on the other side of the fence.
Fire or explosion if transit van is involved in a road traffic incident with fire.
Asphyxiant/flammable atmosphere if the gases are released inside the transit van. / E,
C,
TP / Manual handling training – cylinders moved short distances by churning.
Magnetic signs available in van when transporting DG
Purpose built gas cylinder pallet provided as part of the supply contract for moving cylinders with FLT.
Purpose built gas cylinder trolley available for handling single gas cylinders over short distances.
Tail-lift on transit van to lift gas cylinders in and out of van.
Two man lift for handling on and off the transit vans.
Personnel who change/handle cylinders are trained and competent.
Gas cylinders are restrainedin the upright position with metal chainson a firm level surface when stored to prevent falling.
Restraints in the van capable of safely securing up to three large gas cylinders in the upright position.
Short distance between B99 and H61 circa 300 yards and cylinders removed from transit van immediately on arrival.
Gas cylinders stored outside (except when in use) with adequate ventilation.
Leak check on completion of riginstallation.
Foam fire extinguishers (x 2) located adjacent to storage area.
PPE available
-Riggers or thermal gloves
-Safety footwear.
Gas cylinders separated from boundary with the social club by over 1 metre (actual circa 3 metres).
Propane and O2 separated by at least 3 metres. / 3 / 1 / 3 / 2kg fire extinguisher required following purchase of new vans, all to be checked / DB / ASAP
3 / Dry grinding of ferrous metals using Wolf 8364 200mm pedestal mounted grinding wheels. / Contact with flying objects e.g. bursting wheel, molten metal sparks and dusts, resulting in impact to body and eyes.
Defective equipment.
Contact of the body with rotating abrasive surfaces and abrasive wheels.
Entanglement with rotating parts of machinery.
Trapping between wheel and work rest.
Incorrect/defective/contaminated wheels.
High levels of noise and vibration
Exposure to grinding dusts containing ferrous metals. / E, C / Fixed adjustable guards are fitted and are in efficient state, efficient working order and good repair and are adjustable to suit work.
Adjustable work rest in place.
Grinder and wheels are visually inspected before use.
Equipment inspected in accordance with the frontline maintenance programme.
Warning signs
-Wear hearing protection.
On/off switches are on grinder and easily accessible.
Two personnel trained to use, dress and mount the abrasive wheels.
PPE available
-Goggles
-Dust masks
-Hearing protection
Speed marked on machine 2950/min.
Hard wired electrical supply. / 3 / 2 / 6 / Safe operating procedure to be developed covering High Risk hazards / warning, pre-use checks precautions and PPE.
Refresher training course for those who dress and mount wheels / DB
MC/ST/DB / End Feb 16
ASAP
4 / The cutting of wood, sheet materials inclusive of MDF and plastics on ALTENDORF F45 bench circular saw. / Contact of hands with rotating blade when feeding, adjusting or removing work piece.
Exposure to high noise levels.
Manual handling of sheet materials.
Unauthorised use by untrained staff.
Defective equipment e.g. damaged guards or blunt saw blades.
Exposure to dusts e.g. MDF
Struck by flying debris e.g. off-cuts, chippings. / E,
C / Fixed adjustable guards are fitted over the top of the blade which are in efficient state, efficient working order and good repair.
Two types of fixed adjustable guards available for straight and bevelled cutting.
Machine enclosed beneath the work table.
Riving knife fitted.
Rip fence for work piece support.
Push sticks used as per HSE guidance.
Two emergency stop buttons installed with run down timer with braking device within 10 seconds.
Dust is controlled by LEV29 which is fitted to the top guard and to the bottom enclosure.
Statutory inspection completed on LEV annually by a competent person.
No lone working permitted.
Key control in place for authorised users only.
Correct diameter saw blade fitted and inspected before use. Minimum saw blade diameter specified on machine.
Extension table for large pieces.
Equipment inspected in accordance with the frontline maintenance programme (The HSE guidance on braking of blade is checked).
PPE available
-Goggles,
-Dust masks
-Hearing protection. / 3 / 2 / 6 / Safe operating procedure to be developed covering High risk hazards / warning, pre-use checks precautions and PPE.
Display laminated A3 copy of the HSE poster – Circular Sawing Machines / DP / DB
MC / End Feb 16
Complete / 3 / 1 / 3
5 / Cutting of wood, plastics on
-De-Walt DW 708-GB Chop saw
-Makita 2400B Chop saw
located in wood working machine shop B99. / Contact with rotating blade.
Exposure to high noise levels,
Struck by flying off-cuts causing injury to eyes and body
Exposure to dusts.
Defective equipment e.g. blunt blades. / E,
C / Fixed self-adjusting guards fitted which are inefficient state, efficient working order and good repair.
Dust collection bag is in place on saw.
Warning sign:
-Hearing protection to be used
Hold to run control (dead man handle).
Equipment is visually inspected before use.
Equipment inspected in accordance with the frontline maintenance programme.
Equipment is double insulated and CE marked.
PPE available
-Goggles,
-Dust masks
-Hearing protection / 3 / 2 / 6 / Safe operating procedure to be developed covering High Risk hazards / warning, pre-use checks precautions and PPE. / DP / DB / End Feb 16 / 3 / 1 / 3
6 / Use of Paslode IM65 F16 gas –operated Nailer (nail gun) when fabricating various timber constructions. / High noise levels
Struck by flying debris from timber material.
Pressurized flammable hydrocarbon gas cartridge. / E,
C / Manufacturer’s manual available within the carrying case.
Built in safety features – nose guard must be retracted sufficient distant to activate firing mechanism.
Vibration labels in place
Equipment is double insulated and CE marked.
Only plant maintenance personnel authorised to use Nailer,
PPE available:
-Goggles
-Hearing protection. / 3 / 1 / 3
7 / Checking electrolyte levels of the MEWPs in H61and topping up with distilled water / Splashes of battery acid (irritant) on eyes and skin.
Spark igniting hydrogen gas which is given off during recharging. / E / A manual fill is currently used in house
MEWPs are taken off charge prior to check.
Check is carried out in well-ventilated area.
PPE available
-Safety glasses
-Disposable nitrile gloves. / 2 / 1 / 2 / FIO: A review of MEWP provision is underway which is likely to result in a fullycontracted lease. This will eliminate the need to perform this task in-house.
8 / Fault finding on live electrical plant and equipment up to 400volts.
NOTE: This type of work is rare. / Inadvertent exposure to live electrics resulting in electrocution and / or death. / E / No live working is permitted unless it is not reasonable in all circumstances for equipment to be dead and it is reasonable in all circumstances for the work to be carried out live.
Only fully trained and qualified electrician to work on live equipment.
Use of insulated tools 1000Vwhich are in good condition and fit for purpose.
Erection of barriers around equipment being worked on.
No lone working accompany person to aware of safe isolation procedure.
Footwear is insulating and conducting / 5 / 2 / 10
9 / Movement of vehicles in and out of diesel / waste compound.
Delivery of diesel fuel.
Storage of diesel fuel.
Refuelling vehicles e.g. fork lift truck and tug with diesel fuel. / Pedestrians being struck by moving vehicles if exiting B99 via the office side access door.
Diesel spill whilst pumping or overfilling storage tank.
Fires due to flammable liquids.
Exposure to Irritant / E,
C / Trained and competent vehicle driver.
Competent persons only to drive and fuel vehicles with current valid drivers’ licence and Airside Drivers Permit.
Bulk storage tank for Diesel is located in B99 compound which is a restricted access area.
Hand pump on diesel tank minimises the potential for any spills.
Spill kit available.
Double skin tank with integral bond and level detection.
Two foam fire extinguishers located near-by.
Vision panels in the B99 access doors.
Step by the access door creates a barrierwhich will prevent the vehicle getting too close to building and any pedestrians.
Very limited vehicles movements in the area.
MSDS and COSHH Assessment available on SYPOL. / 3 / 1 / 3 / 3 / 1 / 3
10 / The use of pillar drills floor
-Sealey GDM200A (240 V) with chuck key
-CORONA 15AY (400 V) No chuck / Contact with swarf.
Exposure to dusts.
Entanglement of hair, clothing, gloves with rotating parts of machinery.
Struck by spinning work piece.
Defective equipment.
Contact with cutting fluids AKWESOL 554 – Irritating to eyes. / E,
C / Fixed adjustable guards in place which are in efficient state, efficient working order and good repair.
Foot operated emergency stop switch installed.
No gloves or lose clothing to be worn while operating pillar drills.
Clampto secure work piece to bed of the drill.
Visual inspection performed before use.
Equipment inspected in accordance with the frontline maintenance programme.
PPE available:
-Goggles,
-Dust masks (MDF). / 2 / 2 / 4 / Safe operating procedure to be developed covering high risk hazards / warning, pre-use checks precautions and PPE. / DP / DB / End Feb 16 / 2 / 1 / 2
11 / The use of portable hand held 240V percussion drills x 2
-MAKITA 3000C
-Bosch GBH 2-24DFR / Exposure to high noise levels,
Struck by flying debris
Struck by drill piece shattering
Exposure to dust of material being drilled.
Defective equipment. / E,
C / Visual inspection of equipment before use.
Tools are double insulated and CE marked.
PPE:
-Goggles
-Dust masks
-Hearing protection. / 2 / 2 / 4
12 / Operating portable Bosch jig saw (GST 135 BCE) to cut various materials. / Exposure to high noise levels,
Struck by flying debris e.g. swarf, chippings
Exposure to dusts.
Defective equipment.
Contact with moving blade of jig saw. / E,
C / Visual inspection of equipment before use.
Equipment is double insulated and CE marked
To be operated in accordance with manufacturers operating instructions.
PPE:
-Goggles,
-Dust masks