Occupational Health and Safety Risk Assessment for Cosmetics and Plastics Manufacturing Facility

Assessment Date: [DATE]

Assessor: [ASSESSOR NAME]

Department/Area: [DEPARTMENT/AREA]

Review Date: [REVIEW DATE]

1. Assessment Scope

This risk assessment covers routine and non-routine occupational health and safety risks associated with the cosmetics and plastics manufacturing operations at a large integrated facility, including skin care product production, plastic bottle and cap manufacturing using IBM, IMM and BIM machines, polybag shrink tunnel and sleeving operations, laboratory activities, white oil and glycerin storage tanks, finished goods warehouses, loading bays, LPG area, boilers, RO plant, ETP, compressors, chillers, cooling towers, recycling systems, agglomerators, and molten plastic reprocessing. The assessment includes production, maintenance, warehousing, utilities, material handling, laboratory work, waste handling, and contractor activities. It also considers start-up, shutdown, cleaning, purging, maintenance, breakdown response, and emergency conditions. Exclusions: detailed process design verification, structural engineering certification, and product quality assurance are outside the scope of this document. Administrative fields such as project name, document number, department, names, phone numbers, and dates are intentionally left blank for completion by the employer.

2. Risk Assessment Methodology

A structured HIRA/JSA approach was used to identify hazards by area, process, task, and equipment, then evaluate the likelihood and severity of credible consequences before and after controls. The assessment applies the hierarchy of controls in the following order: elimination, substitution, engineering controls, administrative controls, and PPE. Risk ratings are expressed using a consistent qualitative scale: Likelihood (Rare, Unlikely, Possible, Likely, Almost Certain), Severity (Negligible, Minor, Moderate, Major, Catastrophic), and Overall Risk Rating (Low, Medium, High, Extreme). The assessment is intended to support task-level job hazard analysis for complex operations and to guide site-wide risk reduction, emergency preparedness, training, monitoring, and review.

3. Risk Matrix Reference

The following matrix is used to evaluate risk levels based on likelihood and severity:

		Likelihood
Rare	Unlikely	Possible	Likely	Almost Certain
Severity	Catastrophic	Low	Low	Low	Low	Medium
Major	Low	Low	Medium	Medium	High
Moderate	Low	Medium	Medium	High	High
Minor	Medium	Medium	High	High	Extreme
Negligible	Medium	High	High	Extreme	Extreme

4. Hazard Identification and Risk Evaluation

1. Entanglement, crushing, and amputation hazards at IBM, IMM, and BIM machines, including moving platens, clamps, feed screws, ejectors, and point-of-operation areas during normal production, purging, and mold changes.

Potential Consequences: Workers may suffer crushing injuries, avulsions, amputations, fractures, and severe burns if hands or body parts enter the danger zone or if guarding is missing, bypassed, or improperly installed. Unexpected machine movement during maintenance or mold change can also cause fatal injuries.

Affected Persons: Machine operators, setters, maintenance technicians, supervisors, cleaners, and nearby workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate exposure by using automated handling and remote adjustment where feasible.
• Install fixed guards, interlocked movable gates, two-hand controls, presence-sensing devices, and point-of-operation barriers appropriate to each machine type.
• Apply lockout/tagout for mold changes, clearing jams, maintenance, and purging activities; verify zero energy before access.
• Use written machine-specific SOPs, permit-to-work controls, and only allow trained authorized operators and maintenance personnel.
• Provide task-specific PPE including safety glasses or goggles, heat-resistant gloves where hot surfaces are present, and safety footwear.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

2. Exposure to molten plastic, hot runners, heated barrels, shrink tunnels, sleeving equipment, and hot surfaces during plastics processing and packaging operations.

Potential Consequences: Contact burns, heat stress, ignition of combustible materials, and secondary injuries from startled reactions or spills may occur. Hot splashes can also damage eyes and skin.

Affected Persons: Operators, maintenance staff, quality inspectors, cleaners, and contractors working near hot equipment.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Major	High

Control Measures

• Substitute lower-temperature process settings or safer materials where product specifications allow.
• Engineer heat shields, insulated guarding, temperature interlocks, and restricted access zones around hot equipment.
• Implement safe start-up and shutdown procedures, hot-work style precautions for maintenance, and clear signage for hot surfaces.
• Train workers on burn prevention, safe purging, and emergency first aid for thermal injuries.
• Provide flame-resistant or heat-resistant gloves, long-sleeved protective clothing, eye protection, and safety footwear.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

3. Chemical exposure from glycerin, white oil, adhesives, cleaning agents, laboratory reagents, and process chemicals used in cosmetics production, maintenance, and sanitation.

Potential Consequences: Skin and eye irritation, dermatitis, respiratory irritation, chemical burns, sensitization, and contamination of products or work areas may occur. Spills can also create slip hazards and environmental releases.

Affected Persons: Production workers, laboratory personnel, sanitation staff, maintenance workers, warehouse staff, and emergency responders.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Use SDS-based chemical risk assessment and substitute less hazardous products where practicable.
• Provide local exhaust ventilation, closed transfer systems, spill containment, and eyewash/safety shower stations near use points.
• Store chemicals in compatible, labeled containers in cool, dry, well-ventilated areas away from heat and oxidizers; keep containers tightly closed.
• Implement chemical handling SOPs, spill response procedures, and restricted access to chemical storage and dosing areas.
• Provide chemical-resistant gloves, goggles or face shields, protective clothing, and respiratory protection where exposure assessment indicates need.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

4. Fire and explosion hazards from LPG storage and use, flammable adhesives and solvents, static discharge, ignition sources, and accumulation of vapors in confined or poorly ventilated areas.

Potential Consequences: A fire or explosion could cause fatalities, severe burns, structural damage, production loss, and off-site impact. Secondary explosions may occur if containers are heated or vapors migrate to ignition sources.

Affected Persons: All site personnel, contractors, visitors, emergency responders, and potentially neighboring occupiers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate unnecessary flammable inventories and substitute less flammable products where feasible.
• Install gas detection, explosion-proof electrical equipment where required, bonding and grounding for transfer operations, and adequate mechanical ventilation.
• Segregate LPG and flammable storage from ignition sources, traffic routes, and incompatible materials; maintain clear emergency access.
• Enforce no-smoking, hot-work permitting, non-sparking tools, and strict control of static electricity.
• Provide fire detection, automatic suppression where appropriate, emergency shutdowns, and trained fire wardens with suitable extinguishers and evacuation procedures.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Catastrophic	High

5. Pressure system hazards from boilers, compressors, chilled water systems, RO plant, pressurized lines, and tanks, including stored energy release and vessel failure.

Potential Consequences: Sudden release of pressure can cause blast injuries, projectile hazards, scalding, hearing damage, and fatal trauma. Failure of safety devices may also lead to fire, flooding, or process interruption.

Affected Persons: Utilities operators, maintenance technicians, contractors, and nearby production workers.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Maintain pressure relief devices, gauges, interlocks, and isolation valves in serviceable condition.
• Apply preventive maintenance, inspection, and certification programs for boilers, compressors, and pressure vessels.
• Use lockout/tagout and depressurization procedures before maintenance or line opening.
• Restrict access to utility rooms and train operators in abnormal condition recognition and emergency shutdown.
• Provide hearing protection, eye protection, gloves, and task-specific PPE during maintenance and inspection activities.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

6. Electrical hazards from motors, control panels, heaters, pumps, conveyors, laboratory equipment, wet areas, and temporary contractor installations.

Potential Consequences: Electric shock, arc flash, burns, ignition of flammable atmospheres, equipment damage, and fatal electrocution may occur, especially during maintenance or in wet environments.

Affected Persons: Electricians, maintenance staff, operators, contractors, and cleaners.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Catastrophic	Extreme

Control Measures

• Eliminate exposed live work except where strictly justified and authorized.
• Use engineering controls such as proper enclosure ratings, grounding, residual current protection, and arc-flash labeling.
• Implement electrical isolation, lockout/tagout, test-before-touch, and permit controls for energized work.
• Keep panels closed, dry, and unobstructed; prohibit unauthorized access and temporary unsafe wiring.
• Provide insulated gloves, arc-rated clothing where required, dielectric footwear, face protection, and electrical safety training.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	High

7. Manual handling, repetitive motion, and ergonomic strain from bagging, packing, palletizing, laboratory pipetting, drum handling, and warehouse picking.

Potential Consequences: Musculoskeletal disorders, back strain, shoulder injuries, hand/wrist disorders, fatigue, and reduced productivity may result. Poor ergonomics can also increase error rates and incident likelihood.

Affected Persons: Production workers, warehouse staff, laboratory staff, and cleaners.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Moderate	High

Control Measures

• Eliminate unnecessary manual lifts through mechanized handling, conveyors, lift tables, and pallet trucks.
• Redesign workstations to reduce reach, twist, lift height, and repetitive force.
• Rotate tasks, set load limits, and schedule micro-breaks for repetitive work.
• Train workers in safe lifting, pushing, pulling, and workstation adjustment.
• Provide gloves with suitable grip and other PPE only as a supplement to ergonomic controls.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Minor	Medium

8. Vehicle and pedestrian interface hazards in loading bays, warehouses, raw material receiving, finished goods dispatch, and internal transport routes.

Potential Consequences: Struck-by, crush, and collision injuries may occur involving forklifts, trucks, pallet jacks, and pedestrians. Falling loads can also cause serious injury or product damage.

Affected Persons: Drivers, forklift operators, warehouse workers, contractors, visitors, and security personnel.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Likely	Major	High

Control Measures

• Separate pedestrians and vehicles through marked routes, barriers, one-way systems, and controlled crossing points.
• Use trained and authorized operators only, with pre-use checks for forklifts and lifting equipment.
• Apply speed limits, reversing controls, spotters where needed, and loading bay exclusion zones.
• Manage dock operations with wheel chocks, dock restraints, and communication protocols between drivers and warehouse staff.
• Require high-visibility clothing, safety footwear, and site traffic induction for all personnel and visitors.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Major	Medium

9. Biological, chemical, and confined-space-like hazards associated with ETP, drains, sumps, cooling towers, and wastewater handling areas.

Potential Consequences: Exposure to contaminated water, slippery surfaces, toxic gases, oxygen deficiency, skin infections, and environmental releases may occur. Poor control can also lead to slips, falls, and equipment damage.

Affected Persons: ETP operators, maintenance staff, contractors, laboratory staff, and cleaners.

Initial Risk Assessment

Likelihood	Severity	Risk Rating
Possible	Major	High

Control Measures

• Eliminate entry into tanks and confined spaces unless essential and authorized.
• Use gas testing, ventilation, isolation, and permit-to-work systems for any confined or hazardous entry.
• Maintain housekeeping, drainage, and bunding to prevent slips and uncontrolled discharge.
• Provide biological and chemical hazard awareness, spill response, and wastewater handling procedures.
• Use waterproof gloves, boots, eye protection, and respiratory protection where exposure assessment requires it.

Residual Risk Assessment

Likelihood	Severity	Risk Rating
Unlikely	Moderate	Medium

5. General Control Measures

• Implement a site-wide HIRA/JSA program for all routine and non-routine tasks, with pre-task briefings for high-risk work and documented controls for maintenance, cleaning, and changeovers.

Use task breakdowns for machine operation, chemical handling, utility work, warehouse operations, and contractor activities. Update JSAs when equipment, materials, or methods change.

• Maintain a robust permit-to-work system for hot work, confined space entry, electrical isolation, line breaking, lifting operations, and contractor work.

Permits should define hazards, isolations, gas testing, fire watch, supervision, and emergency arrangements before work starts.

• Provide and enforce a comprehensive PPE program based on hazard assessment and SDS review.

Minimum site PPE should be supplemented by task-specific PPE such as eye/face protection, hand protection, hearing protection, respiratory protection, head protection, foot protection, and torso protection as required by the task.

• Establish preventive maintenance and inspection systems for machines, pressure systems, electrical installations, lifting equipment, fire protection systems, and ventilation systems.

Track defects to closure, remove defective equipment from service, and verify guarding, interlocks, alarms, and emergency stops during inspections.

• Strengthen housekeeping, segregation, and storage controls across production, warehouse, and utility areas.

Keep aisles clear, control spills immediately, segregate incompatible chemicals, store materials securely, and maintain clear access to exits, extinguishers, and emergency equipment.

6. Emergency Preparedness

• Develop and drill an integrated emergency response plan covering fire, explosion, chemical spill, gas leak, boiler or pressure failure, electrical incident, medical emergency, and evacuation. The plan should define alarm activation, muster points, incident command, communication, and liaison with external responders.
• Provide spill kits, absorbents, drain covers, non-sparking tools, and containment materials in chemical storage, laboratory, loading, and utility areas. Large spills should be isolated, ventilated, and prevented from entering drains or watercourses.
• Equip high-risk areas with suitable fire detection and firefighting equipment, including extinguishers matched to the hazard class, and ensure fire wardens are trained in initial response and evacuation control.
• Install and maintain eyewash stations and safety showers near chemical handling and laboratory workstations, and ensure workers know the immediate first-aid response for chemical splashes and thermal burns.
• Prepare rescue and isolation arrangements for utility rooms, tanks, and any confined or restricted spaces, including atmospheric testing, standby attendants, and rescue coordination before entry.

7. Training Requirements

• Machine Safety and Guarding Training: Operators, setters, and maintenance personnel must be trained on machine-specific hazards, guarding systems, interlocks, emergency stops, safe clearing of jams, and the prohibition on bypassing safeguards. Training should include the point of operation, pinch points, nip points, and safe restart procedures.
  • IBM, IMM, BIM, granulators, agglomerators, and shrink tunnel equipment
  • Recognition of defective guards and reporting requirements
  • Safe use of two-hand controls and interlocked gates
• Lockout/Tagout and Energy Isolation Training: Authorized employees must be trained to isolate electrical, pneumatic, hydraulic, thermal, and mechanical energy before maintenance, cleaning, mold changes, line breaking, or troubleshooting. Training should emphasize verification of zero energy and group isolation where multiple workers are involved.
  • Electrical isolation and test-before-touch
  • Depressurization and stored-energy release
  • Shift handover and re-energization controls
• Chemical Safety and SDS Awareness Training: Workers handling glycerin, white oil, adhesives, laboratory reagents, cleaning chemicals, and wastewater-related chemicals must understand SDS information, labeling, incompatibilities, ventilation needs, spill response, and PPE selection. Training should also cover safe storage and environmental protection.
  • Chemical labeling and compatibility
  • Use of eyewash and safety shower equipment
  • Spill containment and waste segregation
• Fire, Explosion, and LPG Emergency Training: Personnel in LPG, boiler, adhesive, solvent, and utility areas must be trained in ignition source control, gas leak recognition, evacuation, emergency shutdown, extinguisher selection, and reporting procedures. Fire wardens and responders require additional practical drills.
  • No-smoking and hot-work controls
  • Static electricity and bonding/grounding
  • Evacuation and muster accountability
• Warehouse, Traffic, and Manual Handling Training: Forklift operators, warehouse staff, and loading bay personnel must be trained in traffic segregation, load stability, reversing controls, dock safety, pedestrian awareness, and safe lifting techniques. Supervisors should reinforce route discipline and exclusion zones.
  • Pedestrian and vehicle separation
  • Safe stacking and pallet integrity
  • Use of spotters and communication signals

8. Monitoring and Review

Review Frequency: Annually and after any incident, process change, equipment modification, significant near miss, or regulatory change.

Monitoring Type	Frequency	Responsible Party	Description
Regular Inspection	Daily and pre-use	Shift supervisors and equipment operators	Inspect machine guards, emergency stops, interlocks, housekeeping, spill conditions, and obvious defects before operations begin. Remove defective equipment from service immediately and escalate for repair.
Preventive Maintenance Verification	Monthly and per manufacturer schedule	Maintenance manager and utilities supervisor	Verify the condition of boilers, compressors, chillers, cooling towers, pumps, electrical panels, ventilation systems, and pressure relief devices. Record defects, corrective actions, and re-test results.
Chemical Exposure and Storage Audit	Monthly	EHS officer and warehouse/production supervisors	Check chemical labeling, segregation, container integrity, ventilation, spill readiness, eyewash access, and compliance with SDS storage requirements. Review any signs of leakage, contamination, or incompatible storage.
Traffic and Warehouse Safety Inspection	Weekly	Logistics supervisor and security team	Inspect pedestrian routes, forklift routes, dock controls, speed compliance, stacking stability, and loading bay controls. Confirm that exclusion zones and signage remain visible and effective.
Safety Performance Review and Incident Trend Analysis	Quarterly	EHS manager and site leadership team	Review incidents, near misses, corrective actions, training completion, permit compliance, and audit findings. Use trends to update controls, priorities, and resource allocation.

9. Special Circumstances

• Night work increases the likelihood of visibility-related incidents, fatigue, and reduced supervision. Additional lighting, communication checks, and supervision are required for maintenance, loading, and security-sensitive tasks.
• Rainy weather and wet floors increase slip, vehicle, and electrical risks, especially in loading bays, external storage areas, and utility yards. Drainage, anti-slip controls, and weather-specific housekeeping must be strengthened.
• Lone work in utility rooms, warehouses, laboratories, or after-hours maintenance increases response time in an emergency. A buddy system, check-in procedure, and escalation protocol should be used where practicable.
• Contractor work introduces unfamiliar hazards, simultaneous operations, and interface risks. Contractors must be inducted, supervised, and controlled through permits, isolation verification, and site rules.
• Heat stress may increase in boiler areas, around hot process equipment, and during outdoor work. Work-rest cycles, hydration, and acclimatization should be managed during hot conditions.

Approval and Sign-off

This risk assessment has been reviewed and approved by:

Assessor: _________________________ Date: __________

Manager/Supervisor: _________________________ Date: __________

Safety Representative: _________________________ Date: __________

This risk assessment must be reviewed annually and after any incident, process change, equipment modification, significant near miss, or regulatory change. or when significant changes occur.

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