Task 1

(a)

1. Independent auditor selection: Worker A, from a different department, was chosen to maintain
impartiality during the audit process, ensuring objectivity and independence in evaluation.

2. Clear communication of audit plans: The health and safety manager (HSM) communicated audit
details early on via email to the production manager (PM), giving them ample time to prepare
for the audit.

3. Thorough planning: The audit process was carefully planned by the HSM, covering multiple
critical stages like delivery, production, storage, and movement of materials, ensuring a
comprehensive assessment of operations.

4. On-the-job training for Worker A: The decision to have Worker A accompany the HSM provided
hands-on training during the audit, enhancing their practical understanding of the health and
safety processes.

5. Flexibility in conducting the audit: Despite initial challenges with the PM and Supervisor B not
being informed, the HSM showed flexibility by proceeding with the audit, ensuring important
issues were still addressed in a timely manner.

6. In-depth observation of production processes: The HSM observed various activities, such as the
loading of raw materials, mixing, and movement of finished products, providing a detailed
insight into the operations and identifying potential risks.

7. Checking for document compliance: The HSM requested and reviewed key documents such as
risk assessments and maintenance logs, identifying outdated documentation, and suggesting
improvements for better compliance.

8. Identification of safety compliance – Physical observation: During the audit, the workers were
observed following correct PPE usage as specified in the risk assessment, demonstrating a
positive culture of safety awareness.

9. Proactive assessment of housekeeping issues – Physical Observation: The HSM identified poor
housekeeping practices, such as chemical spillages and blocked emergency exits, which could
have otherwise led to more serious safety hazards.

10. Worker interview as evidence: The HSM spoke with Worker C, allowing them to voice concerns
about their working conditions, which highlighted critical issues such as dermatitis and fatigue,
leading to a more worker-centric approach.

11. Detailed hazard identification: The audit process helped uncover major hazards like chemical
spills, worn seals, and corroded equipment, prompting necessary improvements.
 12. Structured audit reporting: After gathering information, the HSM classified findings into Good
Practice (GP), Opportunities for Improvement (OFI), and Non-Compliance (NC), ensuring a well-
organized and action-focused audit report.

(b)

Importance of Regular Management Reviews of HSMS and Audit Findings:

1. Identifies weakness Issues: Regular reviews help detect weaknesses or systemic issues within
the Health and Safety Management System. For example, in the scenario, the audit identified
outdated risk assessments and poor housekeeping practices, which could have led to safety
incidents.

2. Ensures legal Compliance: Regular reviews ensure that the organization is always compliant with
changing laws and regulations. In the scenario, reviewing audit findings like missing accident
investigations helps ensure adherence to legal reporting requirements.

3. Active monitoring tools - Improves Risk Management by detecting substandard practices: A

management review allows for proactive identification of new or existing risks. For example, the
audit found spilt chemicals and blocked exits, which could cause accidents. Regular reviews help
address these risks promptly.

4. Help to set priorities: The findings from audits inform management's decision-making process.
The review in the scenario led to the decision to implement a bulk delivery system for chemicals,
improving both safety and productivity.

5. Promotes Continuous Improvement: Regular reviews of audit findings drive improvements

within the organization.

6. Ensures Corrective Actions Are Taken: Reviews ensure that corrective actions are taken based
on audit findings. At the monthly management meeting, where health and safety is always
reviewed, the senior management team are happy with progress. The targets for a reduction in
incidents and accidents, and increased production capacity, that were set last year, have been
achieved.

7. Promote the Safety Culture: Regular management reviews demonstrate a commitment to

health and safety, reinforcing a strong safety culture.
Task 2

1. Introduction of Bulk Chemical Delivery: the Switching from 25-litre drums to the bulk tanker
deliveries would require changes to storage and handling procedures, and the design of new
storage tanks and transfer systems.

2. Planned Preventive Maintenance (PPM) Schedule Changes: introduction of the new equipment
like pumps and the storage tanks would require updates to the preventive maintenance
schedule.

3. Change in the Chemical Handling Practices: Move from manual handling of chemicals to
automatic pumping systems could pose new risks such as pressure-related issues or hose failure,
requiring risk assessments and control measures.

4. New Equipment Installation and segregation between hazardous activities and the other
activities : The installation of pumps, storage tanks, and pipework requires engineering controls,
risk assessments, and training, all of which need to be managed and controlled.

5. changing the SSOWs: The new equipment could introduce new risks such as leaks, explosions, or
chemical exposure, requiring revised safety procedures and MOC controls.

6. Impact on Worker Duties and training plans: The reduction in manual handling of chemicals and
the automation of some processes could change workers’ roles, which would require updating
training, procedures, and possibly PPE usage.

7. Emergency Response Procedures: The new bulk storage system and changes in chemical
handling require updates to emergency procedures, such as spill response and fire safety
measures, all of which must be reviewed and controlled.

8. Impact on PPE Requirements: As chemicals are now pumped rather than manually handled, the
change may alter the required PPE (e.g., gloves, goggles), necessitating a review and update of
PPE protocols.

9. Changes in Work Environment: The changes to the production area may result in modifications
to ventilation, lighting, or fire suppression systems, requiring review under MOC procedures.

10. Impact on the Workforce welfare facilities: The new system may require new or updated
training for workers to understand the risks and safe operation of the new system. This change
must be managed to ensure compliance and safety.
Task 3

Recommended Training to Develop Worker Competence in the Production Department:

1. Chemical Handling and Safety: Following the transition to bulk chemical delivery and pumping,
workers should be trained on safe handling practices, potential hazards, and emergency
procedures to ensure they can respond effectively to chemical spills, leaks, or exposure.

2. Operation of New Equipment: Since new pumps, storage tanks, and pipework were installed,
workers need training on the operation, maintenance, and troubleshooting of these systems to
ensure their safe and efficient use.

3. Risk Assessment and Control: Workers should be trained to understand risk assessments,
including the new hazards introduced by bulk chemical handling, and how to apply control
measures to mitigate these risks.

4. Maintenance of New Equipment: As part of the planned preventive maintenance (PPM)

schedule, workers must be trained in the inspection and maintenance of pumps, tanks, and
associated equipment to ensure they remain in good working condition and prevent
malfunctions.

5. PPE Usage and Maintenance: With changes in work practices, workers should be retrained on
the proper use of personal protective equipment (PPE), ensuring that they are aware of new
requirements and can safely wear, maintain, and replace PPE as needed.

6. The new SSOWs: new techniques and new tasks that require human interventions and task
managing.

7. Emergency Response Procedures: Workers should undergo training on updated emergency

response procedures, including spill response, fire safety, and evacuation drills, to ensure they
are well-prepared in the event of an incident.

8. Housekeeping and Cleanliness: workers should receive training on maintaining a clean and safe
work environment, including proper cleaning techniques and disposal of hazardous waste.

9. Health and Safety Policies and Procedures: Training should focus on reinforcing the
organization’s health and safety policies, including any new procedures related to the bulk
delivery system and automated equipment.

10. First Aid: As part of health and safety improvements, workers should be trained in basic first aid
skills, including how to treat chemical burns, cuts, and other potential injuries that could occur
during production.

11. Accident Investigation and Reporting: Workers should be trained in the correct procedures for
reporting accidents and near-misses, in line with the improved reporting culture and to help
maintain a safer working environment.
Task 4

1. Updated Risk Assessments: Regularly review and update risk assessments to reflect current
operations, particularly the handling of chemicals. In the scenario, the risk assessments are three
years old, which may not account for current risks.

2. Proper Chemical Storage Procedures: Establish clear guidelines for the safe storage of chemicals.
In the scenario, chemicals are stored haphazardly around mixers, which increases the risk of
spills. Chemicals should be stored in designated, well-ventilated, and secure areas.

3. Clear Labelling and Signage: Ensure all chemicals are properly labelled with relevant hazard
symbols and handling instructions. The scenario mentions the presence of "no eating or
drinking" signs, but additional signage indicating chemical hazards would enhance safety.

4. Training and Competence for Workers: Regular training on chemical handling procedures should
be mandatory. Workers should understand the proper use of PPE and emergency procedures.
Worker C in the scenario has dermatitis and complaints about inadequate PPE, indicating a lack
of proper training.

5. Developing Safe Systems of Work for All Tasks: Establish safe systems of work (SSOW) for every
task involving chemical handling, ensuring that procedures are followed to minimize risks. In the
scenario, unsafe practices, such as lifting heavy drums and manual handling of chemicals, lead to
injuries and spills.

6. Emergency Response Procedures: Implement clear procedures for chemical spills, leaks, and
accidents. Ensure all workers are familiar with emergency equipment, including eyewash stations
and first aid kits. The first aid kit in the scenario was improperly stored.

7. Records for the Equipment planned preventive Maintenance: Ensure that all equipment used in
the chemical handling process is properly maintained. The lack of maintenance logs for the
mixers in the scenario could result in equipment failures and chemical leaks.

8. Enclosed supervision for the workers in imminent risks: Restrict access to areas where
hazardous chemicals are stored and used. The scenario shows workers bypassing the emergency
exit door, leading to potential safety hazards.

9. Permit to Work (PTW): Introduce a PTW system for high-risk tasks such as chemical handling,
machinery maintenance, or working in confined spaces. PTWs ensure that workers only carry out
tasks if they are deemed safe, with all necessary precautions in place. In the scenario, there was
no clear indication of such controls in place, particularly with handling chemicals and carrying
out maintenance.

10. Reduce exposure & reduce the time of exposure???

Task 5

1. Reduction in Accidents and Injuries

Fewer accidents and injuries reduce costs related to medical treatment, workers’ compensation
claims, and insurance premiums. The scenario notes several incidents involving chemical spills
and manual handling injuries. Reducing these incidents leads to financial savings.

2. Minimized Absenteeism
Less absenteeism due to fewer injuries, such as the worker who injured their back carrying
drums, results in financial savings by reducing the need for temporary workers and maintaining
consistent production levels.

3. Improved Productivity
Reducing manual handling and introducing bulk storage systems improves efficiency, as shown
by the reduction in production time from two hours to one hour. Increased production capacity
leads to higher revenue.

4. Reduction in Temporary Worker Costs

By improving health and safety conditions, the need for temporary workers to cover
absenteeism or rush orders is reduced. The scenario highlights that the production team often
used temporary workers, which is an additional cost that can be avoided.

5. Improved Worker Morale and dignity (High Morale Lead to high productivity)
Happy and healthy workers are more likely to stay in the organization, reducing recruitment and
training costs associated with high staff turnover. In the scenario, workers report being happier
after the project, which contributes to retention.

6. Reduction in Material Waste

The current handling of raw materials leads to spillage and waste, which has significant financial
implications, especially since the ingredients are described as expensive. Improving chemical
handling reduces waste and material costs.

7. Avoidance of Regulatory Fines

Failure to report incidents (such as the slip-and-fall incident) to the regulator and not
investigating accidents could result in fines and penalties. By improving the health and safety
system, the organization can avoid these financial penalties.

8. Lower Maintenance Costs

Preventive maintenance reduces long-term costs of repairing or replacing equipment. The
scenario mentions equipment corrosion and the lack of maintenance for six months. Introducing
regular maintenance will prevent costly equipment failures and downtime.

9. Improved Housekeeping Reduces Risks

Improving housekeeping, such as cleaning up chemical spills and clearing blocked exits,
minimizes the risk of accidents. This reduces the likelihood of incidents that could result in costly
legal claims or insurance payouts.
10. Reduced Insurance Premiums
Insurance premiums are often based on the level of risk within a workplace. By improving safety
standards, the organization can negotiate lower insurance premiums, resulting in long-term
financial savings.

11. Increased Productivity by enhancing the health and safety performance

This improvement leads to increased output and higher profitability, as evidenced by the
scenario’s doubling of production speed.

12. Enhanced Reputation and Business Opportunities

Investing in health and safety can enhance the organization’s reputation. A safer workplace
makes the organization more attractive to potential clients, investors, and partners, potentially
leading to new business opportunities.

13. Automation of the process which will help in avoiding the expensive ingredients “In addition to
the health and safety issues of spilt chemicals, they tell you that some of the ingredients are very
expensive and there is a high level of waste”

14. Avoiding Litigation Costs

Improving safety procedures reduces the likelihood of workplace injury claims and potential
lawsuits. The company can avoid the financial impact, including legal fees, and court costs.

15. Lower Turnover and Training Costs

By ensuring worker safety and satisfaction, the company can reduce employee turnover, saving
costs associated with hiring and training new workers. The temporary workers used in the
production area are costly and inefficient.

16. Damage to industrial relations, perhaps leading to industrial action (e.g. strikes)
Task 6

1. Unsafe Workplaces and Equipment (Clause a)

The production area contains chemical spillages, corrosion on the mixer motor, and signs of poor
maintenance, which indicate that the workplace was not maintained in a safe condition. This violates the
obligation to provide and maintain safe machinery and equipment.

2. Lack of Adequate Instructions and Training (Clause b)

Although workers are using PPE, there is no indication that proper training on chemical handling, risk
assessment, and emergency response was provided. Worker C, for example, reports dermatitis from
chemical exposure, suggesting inadequate training regarding safe handling.

3. Inadequate Supervision (Clause c)

Supervisor B was unaware of the planned audit and had difficulty locating safety documents, which
reflects poor supervision of safety practices and record-keeping in the production department.

4. Absence of Effective Organisational Safety Arrangements (Clause d)

The production department’s safety system was not sufficiently organised, as evidenced by the lack of
safety communication, lack of risk assessments updated in the past three years, and improper chemical
storage practices.

5. Failure to Provide PPE Adequately (Clause e)

While workers were wearing PPE (gloves, goggles, and masks), this may not be sufficient protection for
the specific chemical hazards present, and the discomfort caused by gloves, as reported by Worker C,
suggests that the right protective equipment was not provided or not effective.

6. Chemical Storage and Handling (Clause a)

The improper storage of chemicals near mixers, and drums blocking emergency exits, indicates that
health and safety measures to prevent chemical risks were not followed, violating the obligation to
maintain safe workplaces and work methods.

7. Poor Health and Safety Communication (Clause c)

Supervisor B not being informed about the audit shows a lack of communication and a failure to involve
the workforce in safety practices, which is essential for effective supervision and the application of safety
measures.

8. Inadequate Supervision of Risk Assessment Application (Clause c)

The outdated risk assessments (from three years ago) indicate a failure in maintaining up-to-date safety
documentation, and this may have contributed to workers being unaware of the current risks and how to
manage them properly.

9. Lack of Organisational Safety Arrangements (Clause d)

The safety policies were outdated (three years old), showing that the organisation lacked appropriate
safety arrangements and an ongoing review process to adapt to the evolving risks of the production
department.
10. Poor Maintenance and Safety Equipment (Clause a)
The absence of routine maintenance logs for equipment like mixers and the presence of worn seals and
corrosion suggests neglect in maintaining safe machinery, which poses a health risk to workers.

11. Inadequate Response to Worker Health Concerns (Clause g)

Worker C’s complaints of tiredness and dermatitis were not addressed by the PM, showing neglect in
managing the physical and mental fatigue of workers, and a failure to eliminate such hazards.

12. Absence of Proper Health and Safety Policy Enforcement (Clause a)

The lack of enforcement of safety policies, such as the improper chemical handling and lack of hazard
mitigation measures, reveals that the employer failed to follow through on maintaining safe and healthy
workplaces.

13. Ineffective Work Methods (Clause a)

The use of forklifts through emergency exit doors and manual handling of heavy chemical drums is an
unsafe work method that puts workers at risk of injury, indicating that the employer has not ensured
safe working practices.

14. Inadequate Training in Safety Procedures (Clause b)

There is no evidence in the scenario that the employees received training in safe chemical handling or
first-aid procedures, which should have been a priority, especially for those working with hazardous
materials.

15. Poor Fatigue Management (Clause g)

The high production demands, increased shifts, and the use of temporary workers suggest that the
employer did not take reasonable steps to manage excessive physical and mental fatigue, which could
increase the likelihood of accidents or errors in the workplace.
Task 7

1. Lack of Communication
The production manager (PM) did not inform the supervisor about the scheduled audit,
reflecting poor communication regarding health and safety priorities. This shows a lack of
commitment from leadership to keep teams informed about crucial HSE processes.

2. Outdated Risk Assessments

The risk assessments were last completed three years ago, indicating that they are not regularly
reviewed. This points to a complacent approach toward hazard identification and control, which
can increase risks over time.

3. Inadequate Response to Reports

Worker C reported their skin irritation and concerns about the dirty work area, but the PM did
nothing. This failure to act on workers' health and safety complaints is a clear indicator that
worker concerns are not taken seriously, eroding trust in the safety management system.

4. Poor Housekeeping
The production area had spillages and empty drums left around mixers, showing poor
housekeeping standards. Spillage-related incidents are not only safety hazards but also suggest
that maintaining a safe environment is not a priority for the workforce or management.

5. Blocked Emergency Exits

Drums were blocking part of the emergency exit, a serious safety violation. This indicates
negligence regarding fundamental emergency procedures and demonstrates a lack of respect for
safety standards.

6. Blocked emergency exit

You can see that some of the drums are currently blocking part of the doorway.

7. Not respecting safety signs “You also notice a ‘no authorised persons beyond this point’ sign on
the exterior of the door. “

8. Delayed Maintenance
Routine maintenance was last recorded six months ago for the mixer, highlighting a failure to
implement and track scheduled maintenance. This neglect could lead to equipment failure and
accidents.

9. Lack of Reporting to the Regulator

The accident involving a worker falling down the mixer stairs was not reported to the regulator.
This disregard for regulatory compliance indicates a failure to take incidents seriously and
manage them transparently.

10. Incomplete Documentation

The supervisor struggled to locate paperwork during the audit, reflecting poor documentation
 management. This lack of organization implies that record-keeping for health and safety is not
prioritized, weakening the integrity of the safety system.

11. Outdated Health and Safety Policy

The organization’s health and safety policy was signed by a previous managing director and is
three years old, suggesting that it has not been reviewed or updated to reflect current risks and
organizational changes.

12. Worker Fatigue and Discomfort

Workers are reportedly tired from extra shifts and find the heavy gloves uncomfortable. This
points to poor consideration for worker welfare, with health and safety taking a backseat to
production demands.

13. Neglecting Incident Investigations

Despite the high number of accidents and near misses in the production department, there is no
evidence of proper investigations being conducted. The failure to investigate these incidents
reflects a negative safety culture, as it shows that management is not learning from mistakes or
taking steps to prevent future occurrences.

These points reveal that the organization’s health and safety culture need substantial improvement to
prioritize worker safety, regulatory compliance, and management accountability.
Task 8

1. Implementation of Health and Safety Management System: The organisation has developed
and implemented a structured health and safety management system (HSMS), which includes
internal auditing and clear audit procedures.

2. Independent Auditors: The use of auditors from various departments ensures independence,
providing a fair and impartial assessment of health and safety practices in the production area.

3. Health and Safety Policy Displayed: A copy of the health and safety policy is prominently
displayed in the production area, showing the organisation's commitment to safety.

4. Correct Use of Personal Protective Equipment (PPE): Workers in the production area are
observed wearing the correct PPE (gloves, goggles, and disposable dust masks), following the
guidelines set in the risk assessments.

5. Health and Safety Training: Workers in the production department are provided with the
necessary training to understand health and safety risks and to operate safely within the
production area.

6. Risk Assessments Completed: Risk assessments for the production area are completed,
demonstrating that the organisation has identified and assessed potential hazards, even though
the documents are dated.

7. Recording and Reporting of Accidents: The organisation correctly records accidents and near
misses in the accident book, reflecting a commitment to documenting health and safety
incidents, even if investigations were not conducted.

8. Auditing Process: Regular audits are scheduled to assess the safety of the production
department, highlighting that the organisation takes a proactive approach to identifying areas
for improvement.

9. Management Review: Senior management conducts regular reviews of health and safety
performance, as evidenced by the monthly management meetings where health and safety
issues are discussed, showing commitment to continuous evaluation and improvement.

10. Continuous Improvement: The organisation recognises areas for improvement in chemical
storage and handling, as evidenced by the audit report, and takes steps to address these issues,
such as the proposal for bulk delivery and storage of raw materials.