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:

1. Notify - Inform affected employees
2. Identify - Identify all energy sources
3. Isolate - Shut down equipment normally
4. Lock/Tag - Apply personal lock and tag
5. Release - Release stored energy
6. Verify - Attempt start to confirm isolation
7. Perform - Complete maintenance work
8. 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

1. Eliminate - Remove need for manual handling
2. Mechanise - Hoists, trolleys, conveyors
3. Reduce - Lighter loads, team lifting
4. 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

1. Immediate - Secure scene, care for injured
2. Report - Complete incident form
3. Investigate - Gather facts, interview witnesses
4. Root cause - 5 Whys, fishbone analysis
5. Actions - Corrective and preventive
6. 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