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