Healthsafety

What this skill does

# 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:**

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 |
|--------