Health & safety & risk assessment

Case Study 1

A cement plant has multiple operations, each of which is controlled by PLCs which are controlled from a central control room in a different building. One of the PLCs for the stone-crushing operation has malfunctioned; it is located inside a cabinet on the wall in the crusher house. It requires replacement.
Task 1, Learning Outcomes 3.1, 3.2, 3.3
Be able to analyse engineering activities for the assessment of risk.

Using the template in the Appendix at the end of this document, start a Risk Assessment for the operation of replacing the PLC. Consider three of the main hazards and complete the template for those only.

Deliverables:Completed Risk Assessment.

Case Study 2

A distribution warehouse for a manufacturing company has vehicles both delivering and collecting from one end and movement of both fork-lift vehicles and people in the main warehouse area. Routes for the road vehicles, lifts and pedestrians are segregated. The company are proposing to undertake a study into the warehouse to make the operation safer, after one worker sustained a minor injury in a collision with a fork-lift truck.

Task 2, Learning Outcomes 3.4, 4.1, 4.2, 4.3, 4.4, 4.5

Be able to manage and minimise risk to life, property and engineering activities within an industrial environment.
Write a report for the company management outlining a strategy for the study. Suggest three different sources of safety / accident data to base the study on and explain how the data can be used to identify hazards and analyse the risks. Explain how the risk analysis can be developed into an action plan for the workplace and suggest how this can be implemented, including any staff training which might be required, and how and when the process should be reviewed.

Deliverables: A report on the strategy for risk reduction. Actual data and detailed recommendations are not required. (Maximum 400 word).

Useful resources:http://www.hse.gov.uk/
• Essentials of Health and Safety at Work (free download from HSE website)
• Management of Health and Safety at Work Regulations 1999
• Workplace (Health, Safety and Welfare) Regulations 1992
• Provision and Use of Work Equipment Regulations 1998
• Control of Substances Hazardous to Health Regulations 2002
• Noise at Work Regulations 2005
• Electricity at Work Regulations 1989
• Health and Safety in Engineering Workshops (free download from HSE website)
• Five Steps to Risk Assessment (free download from HSE website)