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

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

          LIKELIHOOD
          Low    Medium   High
     ┌────────┬────────┬────────┐
High │ Medium │  High  │Critical│

SEVERITY ├────────┼────────┼────────┤ Medium │ Low │ Medium │ High │ ├────────┼────────┼────────┤ Low │ Low │ Low │ Medium │ └────────┴────────┴────────┘

Risk Response

Risk Level Response Required Timeframe

Critical Stop work, immediate action Immediate

High Implement controls before work Within 24 hours

Medium Plan and implement controls Within 1 week

Low Document and monitor Ongoing

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