sample risk register.xlsx
DESCRIPTION
Sample Risk Register Form for API DocumentationTRANSCRIPT
Risk Register
Risk Area/Process Activity Identified Risk Scenario ImpactOverall Risk
Reference Person-in-charge Contingency Action(s)Severity Likelihood Risk Level
0001 business loss 5 C HIGH OGM
0002 Budgeting Unavailable data 3 C MEDIUM OGM
0003 Budgeting Setting goals and targets Setting of unrealistic goals and targets misappropriation of resources 5 D HIGH OGM
0004 Budgeting misinterpretation of goals and targets misappropriation of resources 5 D HIGH OGM
0005 Budgeting miscalculation misappropriation of resources 5 D HIGH OGM
0006 Budgeting misinterpretation/miscalculation misappropriation of resources 5 D HIGH OGM
0007 Budgeting delay in reviewing budget drafts misappropriation of resources 5 D HIGH OGM
0008 Budgeting Revision of budget drafts miscalculation misappropriation of resources 5 D HIGH OGM
0009 Budgeting miscalculation misappropriation of resources 5 D HIGH OGM
0010 Budgeting disapproval 5 D HIGH OGM
0011 Budgeting discrepancy in budget figures misappropriation of resources 5 D HIGH OGM
0012 Budgeting Monitoring performance inaccurate data business loss 5 D HIGH OGM
0013 Budgeting inappropriate analysis 5 D HIGH OGM
0014 failure to indentify certain hazard/impact occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
Risk Register #
Prevention/Mitigation Action(s)
Person-in-charge
Office of the General Manager
Assessment, deployment, implementation, review, and adjustment phase of SBPP
failure to conduct effective strategic business plan
ECA-OGM001
Establish procedure for regular conduct of reviews and deployment meetings
Review of business performance
-delay in business performance review-delay in setting goals and targets
ECA-OGM002
-double time in preparing the budget-rescheduling of the activity
ECA-OGM003
review action plans and variances
Dissemination of goals and target
ECA-OGM003
review action plans and variances
Formulation of action plans and budget
ECA-OGM003
review action plans and variances
Review of action plans and budget
ECA-OGM003
review action plans and variances
Review of action plans and budget
ECA-OGM003
review action plans and variances
ECA-OGM003
review action plans and variances
Review of budget drafts and preparation of master budget
ECA-OGM003
review action plans and variances
Presentation to President for approval
delay in performing projected activity
ECA-OGM003
review action plans and variances
Revision of master budget draft
ECA-OGM003
review action plans and variances
ECA-OGM003
review action plans and variances
Conducting corrective/preventive action
recurrence of problem/business loss
ECA-OGM003
review action plans and variances
Hazard/Aspect Identification and Risk
Assessment
Identification of occupational health and safety hazards/environmental aspects per activity
Choose group of skilled/trained assessor in conducting assessment for brainstorming
FM-RSK004Rev. 00
0015 3 B MEDIUM ECA-EHS004 IMR IMR
0016 failure to identify a certain hazard/impact occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0017 Formulation of controls failure to make controls analysis 3 B MEDIUM ECA-EHS005 IMR
0018 late finalization of reports 3 B MEDIUM ECA-EHS005 IMR
0019 failure to implement the programs occurrence of incident 3 B MEDIUM ECA-EHS001 IMR
0020 failure to make controls analysis 3 B MEDIUM ECA-EHS005 IMR
Hazard/Aspect Identification and Risk
Assessment
Identification of occupational health and safety hazards/environmental aspects per activity
section/department representative not available
delay in conducting the assessment
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Source for back-up resource persons to conduct analysis
Hazard/Aspect Identification and Risk
Assessment
Identification of associated hazards for health, safety and environmental
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Hazard/Aspect Identification and Risk
Assessmentdelay in implementation of needed program
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Hazard/Aspect Identification and Risk
AssessmentFinalization of assessment reports
delay in implementation of needed program
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Hazard/Aspect Identification and Risk
Assessment
Implementation of approved programs/action plans
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Hazard/Aspect Identification and Risk
AssessmentReview of risk assessment and controls
delay in implementation of needed program
Choose group of skilled/trained assessor in conducting assessment for brainstorming
0021 failure to have the update of requirements. 4 B MEDIUM ECA-EHS002 IMR
0022 4 B MEDIUM ECA-EHS002 IMR
0023 Unavailability of SO/PCO delay in updating the register. 3 B MEDIUM ECA-EHS004 IMR
0024 Communication roll out fail to communicate information violation to any requirements 4 B MEDIUM ECA-EHS002 IMR
Identification and Compliance to
Applicable Legal & other requirements
Receipt and review of new laws, regulations, and code of practice, and other requirements
regulatory infractions/customer complaints
-Regular updating of company and other requirement register thru websites/visit to government libraries-Include JIS requirements in the work instructions posted in the work area.-Establish procedure for handling customer complaints.
Identification and Compliance to
Applicable Legal & other requirements
Verification of applicability
Wrong judgment if the requirement is applicable or not.
regulatory infractions/customer complaints
-Regular updating of company and other requirement register thru websites/visit to government libraries-Include JIS requirements in the work instructions posted in the work area.-Establish procedure for handling customer complaints.
Identification and Compliance to
Applicable Legal & other requirements
Update of legal and other requirement register
-Group of skilled/trained assessor is used in conducting the assessment for brainstorming-competence of SO/PCO on updating the register-Competence of SO/PCO in evaluating reports
Source for back-up resource persons to conduct analysis
Internal/External Communication
-Regular updating of company and other requirement register thru websites/visit to government libraries-Include JIS requirements in the work instructions posted in the work area.-Establish procedure for handling customer complaints.
0025 failure to prepare the necessary CA/PA 4 B MEDIUM ECA-EHS002 IMR
0026 failure to circulate the resolutions 4 B MEDIUM ECA-EHS003 IMR
0027 failure to include the necessary CA/PA 4 B MEDIUM ECA-EHS002 IMR
0028 3 B MEDIUM ECA-EHS005 IMR
0029 occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0030 failure to develop emergency procedures occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0031 occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0032 Operational control occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
Internal/External Communication
Processing of CA's and PA's and then conducting
risk Assessmentrecurrence of problem or infractions to requirements
-Regular updating of company and other requirement register thru websites/visit to government libraries-Include JIS requirements in the work instructions posted in the work area.-Establish procedure for handling customer complaints.
Internal/External Communication
Circulation of resolutions (CA's and PA's)
pending of the matter that needs closure
-Maximize processing time for handling customer-coordinate with the requesting party for the reasons of delay
Internal/External Communication
Implementation of CA's and PA's
recurrence of problem or infractions to requirements
-Regular updating of company and other requirement register thru websites/visit to government libraries-Include JIS requirements in the work instructions posted in the work area.-Establish procedure for handling customer complaints.
Emergency Preparedness and
ControlReview of risk assessment result
failure to review the risk assessment results
needed actions may not be implemented
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Emergency Preparedness and
Control
Identification of hazards/aspect that would lead to an emergency.
failure to identify some hazards/aspects of the activity
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Emergency Preparedness and
ControlDevelopment/review of emergency procedures
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Emergency Preparedness and
Control
Implementation of procedure/conducting trainings
failure to implement the established procedures
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Review of the risk assessment result
failure to review the risk assessment results
Choose group of skilled/trained assessor in conducting assessment for brainstorming
0033 Operational control occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0034 Operational control occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0035 Operational control occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0036 Operational control failure to give the training needed occurrence of incident 5 B MEDIUM ECA-EHS001 IMR
0037 Operational control failure to monitor procedure effectiveness 3 C MEDIUM ECA-EHS005 IMR
0038 Incident Investigation 3 D MEDIUM ECA-EHS006 IMR
0039 Incident Investigation delayed treatment 5 B MEDIUM IMR
0040 Incident Investigation failure to evaluate accident report recurrence of the incident 5 B MEDIUM ECA-EHS001 IMR
0041 Incident Investigation 3 B MEDIUM ECA-EHS005 IMR
Identification of medium and high risk aspects/hazards that would require procedural control
failure to identify some hazards/aspects of the activity
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Development of procedures then (4)conducting risk assessment
failure to consider the identified hazard/aspects
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Implementation of procedure
failure to implement the established procedures
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Training of concerned personnel
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Monitoring for compliance effectiveness
necessary corrective action will not be implemented
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Informing supervisor/company nurse of any incident that occurs
failure to inform the concerned supervisor/company nurse
necessary emergency responses may not be done
Established company rules and regulations of incident/accident reporting
Sending victim to treatment
worsening of the victim's situation
ECA-EHS001,
ECA-EHS007
-Choose group of skilled/trained assessor in conducting assessment for brainstorming-Availability of company clinic, nurse and trained first aiders-Employees are provided with health card
Evaluation of accident report then review of
existing HAIRA, EPC, & ERI
Choose group of skilled/trained assessor in conducting assessment for brainstorming
Implementation and monitoring approved recommendation and conducting verification
failure to monitor corrective/preventive actions
necessary corrective actions may not be implemented and effective
Choose group of skilled/trained assessor in conducting assessment for brainstorming
0042 major injury 3 B MEDIUM ECA-EHS007 PCO/SO/ IMR
0043 Records management Filing of records failure to keep important record 4 C MEDIUM IMR/DCC
0044 Records management loss of files,/record 4 C MEDIUM IMR/DCC
0045 Lack of information about the complaint 4 C MEDIUM IMR
0046 Insufficient root cause analysis 4 C MEDIUM IMR
0047 Informing the customer delay closing of complaint 3 C MEDIUM IMR
0048 Internal IMS Audit Actual audit 4 C MEDIUM IMR
0049 Internal IMS Audit Actual audit injury 3 C MEDIUM IMR
0050 Lacking details on support documents 4 C MEDIUM IMR
0051 late submission of report delayed conduct of reviews 3 C MEDIUM IMR
0052 Analysis of Data fail to collect reports delayed analysis 3 C MEDIUM IMR
0053 Analysis of Data Late submission of statistical report 3 C MEDIUM IMR
0054 4 C MEDIUM IMR
0055 4 C MEDIUM IMR
0056 poor root cause analysis 4 C MEDIUM IMR
New Infrastructure/ Equipment Installation
Installation of new equipment and/or infrastructure
Lack of safeguards installed over moving parts of machines installed
-Availability of company clinic, nurse and trained first aiders-Employees are provided with health card
no evidence to present during audits
ECA-QAD001
Established procedure for corrective/preventive action
Monitoring of active and archive files
Fire hazard, unauthorized person enters the records center
ECA-QAD001
Availability of fire extinguisher in the area
Handling Customer Complaints
Receipt and evaluation of complaint
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Handling Customer Complaints
Conducting corrective/preventive action
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Handling Customer Complaints
failure to inform customer about the corrective/preventive action
ECA-QAD003
Established procedure for different QA activities
failure to identify strengths and areas for improvement
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Exposure to hazards on different area scheduled for audit
ECA-QAD004
-Establishment of First Aid Team-Availability of company clinic and nurse
Process Monitoring and Measurement
Preparation of reports supporting performance
indicatorsno evidence to present during audits
ECA-QAD001
Availability of fire extinguisher in the area
Process Monitoring and Measurement
Submission of report to IMR
ECA-QAD003
Established procedure for different QA activities
Receipt of reports from various sections/departments
ECA-QAD003
Established procedure for different QA activities
Forwarding statistical report to concerned Division Manager
delayed implementation of action plan
ECA-QAD003
Established procedure for different QA activities
Corrective/ Preventive Action
Identification of potential/existing nonconformity
Failure to identify potential/existing nonconformity
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Corrective/ Preventive Action
Verification and analysis of potential/existing nonconformity
poor verification & analysis of nonconformity
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Corrective/ Preventive Action
Determining the cause of potential/existing nonconformity
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
0057 formulation of ineffective action plans 4 C MEDIUM IMR
0058 Late implementation of action plans 4 C MEDIUM IMR
0059 4 C MEDIUM IMR
0060 Failure to close out the nonconformity 4 C MEDIUM IMR
0061 Failure to check files and program backup loss of records and program 3 C MEDIUM IT Personnel
0062 loss of records and program 3 C MEDIUM IT Personnel
0063 Failure to quarantine infected files loss of data and program 3 C MEDIUM IT Personnel
0064 Failure to clean infected files loss of data and program 3 C MEDIUM IT Personnel
0065 Failure to copy files to recent backup loss of data and program 3 C MEDIUM IT Personnel
0066 Failure to copy files to recent backup 3 C MEDIUM IT Personnel
0067 exposure to radiation ill health 3 A MEDIUM IT Personnel
0068 Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
0069 Incomplete number of survey results 2 C MEDIUM
0070 Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
0071 3 C MEDIUM
Corrective/ Preventive Action
Solution formulation and update/conduct of risk assessment
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Corrective/ Preventive Action
Implementation of approved action plans
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Corrective/ Preventive Action
Review and recording of actions taken and standardization of implemented action
failure to review the effectiveness of action plans
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Corrective/ Preventive Action
Closing out of the nonconformity
occurrence/recurrence of potential/existing problems
ECA-QAD002
Established procedure on corrective/preventive action
Software and Hardware
MaintenanceBacking up all data (files and programs)
ECA-QAD005
Retrieve data, program for backup
Software and Hardware
MaintenanceBacking up all data (files and programs)
External hard drive is not in good working condition
ECA-QAD005
Retrieve data, program for backup
Software and Hardware
MaintenanceQuarantine of infected files
ECA-QAD005
Retrieve data, program for backup
Software and Hardware
MaintenanceCleaning/healing of infected files
ECA-QAD005
Retrieve data, program for backup
Software and Hardware
MaintenanceCopying clean file(s) to recent backup
ECA-QAD005
Retrieve data, program for backup
Software and Hardware
MaintenanceCopying clean file(s) to recent backup
loss of update data to backup drive
ECA-QAD005
Retrieve data, program for backup
Software and Hardware
MaintenanceConducting preventive maintenance
ECA-QAD006
Customer Satisfaction Determination
Conducting customer survey
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Customer Satisfaction Determination
Gather the issued customer survey
incomplete analysis report for number of customers
ECA-SAM008
Revise procedure to account for monitoring follow-up and timeliness of sending of the survey.
Account Executive, Sales and Marketing
Manager
Customer Satisfaction Determination
Gather the issued customer survey
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Inquiry and Order Handling
Preparation and submission of quotation and drawing
Inaccurate product specification & drawing vs. customer requirement
wrong order/product specifications
ECA-SAM007
Forms are being used to ensure all requirements are properly translated and documented
Account Executive, Sales and Marketing
Manager
0072 Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
0073 Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
0074 Receipt of Job Order Unable to receive job order 4 B MEDIUM
0075 Receipt of Job Order Loss of Job Order Customer complaint 4 B MEDIUM
0076 Receipt of Job Order Late receipt of job orders Delay and production delivery 4 B MEDIUM
0077 Exposure to dust Eye irritation/discomfort 4 C MEDIUM
0078 Wrong encoding of job orders Delayed delivery 3 C MEDIUM
0079 Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
Inquiry and Order Handling
Preparation and submission of quotation and drawing
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Inquiry and Order Handling (Local)
Preparation and signing of job order
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Order Handling (Export)
Delay of delivery to the customer
ECA-SAM001
-Thorough coordination with the customers for the issuance of job orders or purchase orders on time.Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Order Handling (Export)
ECA-SAM001
-Thorough coordination with the customers for the issuance of job orders or purchase orders on time.Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Order Handling (Export)
ECA-SAM001
-Thorough coordination with the customers for the issuance of job orders or purchase orders on time.Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Order Handling (Export)
Checking of stock availability from QC warehouse.
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Order Handling (Export)
Encoding to Job Order then printing and signing Job Order
ECA-SAM002
-Double checking of FVC Job Order vs. FKC Job Order
Account Executive, Sales and Marketing
Manager
Order Handling (Export)
Encoding to Job Order then printing and signing Job Order
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
0080 Prospecting Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
0081 Prospecting Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
0082 Prospecting Exposure to dust, heat and others. illness/discomfort 4 C MEDIUM
0083 Prospecting Incapability of closing the deal No new customer 2 C MEDIUM
0084 Unable to schedule the delivery 4 B MEDIUM
0085 Late receipt of advice 4 B MEDIUM
0086 Unable to schedule the delivery 4 B MEDIUM
0087 Unable to schedule the delivery Customer complaint 4 B MEDIUM
0088 Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
Creating list of prospective customer
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Identification and qualification of potential customer
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Presentation and demonstration
ECA-SAM004
Annual physical examination
Account Executive, Sales and Marketing
Manager
Handling objections and closing
ECA-SAM009
-Cover n action plans for SWOT Analysis for SAM-Additional headcount - Manager and Engineer-API, UL, FM certification
Account Executive, Sales and Marketing
Manager
Delivery(Local & Export)
Receipt of delivery schedule from Production Manager
Delay of delivery to the customer
ECA-SAM005
-Constant monitoring of required delivery date of customers-Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Delivery(Local & Export)
Receipt of delivery schedule from Production Manager
Delay of delivery to the customer
ECA-SAM005
-Constant monitoring of required delivery date of customers-Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Delivery(Local & Export)
Scheduling and determination of delivery destination
Delay of delivery to the customer
ECA-SAM005
-Constant monitoring of required delivery date of customers
Account Executive, Sales and Marketing
Manager
Delivery(Local & Export)
Scheduling and determination of delivery destination
ECA-SAM005
-Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Delivery(Local & Export)
Preparation and signing sales documents
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
0089 Overweight load Penalty to the shipping line 4 C MEDIUM
0090 Overweight load delay delivery to the customer 4 C MEDIUM
0091 Delivery Reckless driving Major injury 5 B MEDIUM ECA-GSD009
0092 Exposure to computer radiation Eye irritation/discomfort 4 C MEDIUM
0093 Collection Customer transferred to another place 5 B MEDIUM Filing of legal action
0094 Collection Customer failure to pay on due date business loss 5 B MEDIUM Filing of legal action
0095 Collection Customer does not have the invoice delay in collection 5 B MEDIUM
0096 Collection Sales invoice different from customer PO 5 B MEDIUM
0097 Collection Legal expenses business loss 5 B MEDIUM
0098 Failure of customer to inform updates business loss q B MEDIUM
0099 5 B MEDIUM
Delivery(Local & Export)
Endorse container/hauler to Production Manager for loading
ECA-SAM006
-Confirmation from Production Manager of actual weight of the items for delivery-Double checking of documents needed for delivery-Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Delivery(Local & Export)
Endorse container/hauler to Production Manager for loading
ECA-SAM006
-Confirmation from Production Manager of actual weight of the items for delivery-Double checking of documents needed for delivery-Established procedure for handling customer complaints
Account Executive, Sales and Marketing
Manager
Delivery(Local & Export)
Delivery(Local & Export)
Exposure to computer radiation
ECA-SAM003
Annual eye examination, use of eyeglasses
Account Executive, Sales and Marketing
Manager
Preparation and monitoring of aging schedule of AR trade then waiting for due date
receivables may not be collected
ECA-SAM010
Account Executive, Sales and Marketing
Manager
Preparation and monitoring of aging schedule of AR trade then waiting for due date
ECA-SAM010
Account Executive, Sales and Marketing
Manager
Follow-up of collection (Sending delinquency/SA)
ECA-SAM011
Meeting with customers for scheduled payment date and settlement
Sales and Marketing Manager
Follow-up of collection (Sending delinquency/SA)
delay in collection/possible business loss
ECA-SAM011
Meeting with customers for scheduled payment date and settlement
Sales and Marketing Manager
Sending delinquency report (preparation of legal action)
ECA-SAM011
Meeting with customers for scheduled payment date and settlement
Sales and Marketing Manager
Customer Accreditation
Receipt of accomplished Customer Information Sheet
ECA-SAM012
-Inform customer-Constant follow-ups
Sales and Marketing Manager
Customer Accreditation
Update of customer database
New customer is added to the existing database
Incomplete analysis report of potential customer
ECA-SAM013
-Inform customerconstant follow-ups
Sales and Marketing Manager
0100 Production Planning Overlook of job orders and specifications Loss of customers 5 B MEDIUM ECA-PRD001
0101 Production Planning Late issuance of JO 3 C MEDIUM ECA-PRD001
0102 Production Planning 3 D MEDIUM ECA-PRD001
Review of JO and drawing from Sales Department
-Implementation of 5S and records management-Established standard procedure for control of documents-Signing of process owners who received the documents-follow up through emailfolder per palletainer - bin control-monthly inventory based on stock card record-Establish procedure for handling customer complaint
Production Manager
-Coordinate with FKC through GM in relation to the early submission of JOB Orders together with the drawings-Monthly physical inventory to be done to address inventory inaccuracy-additional manpower to support physical inventory and other QCD activities
Production Manager
Review of JO and drawing from Sales Department
delay in delivery/customer complaint
-Implementation of 5S and records management-Established standard procedure for control of documents-Signing of process owners who received the documents-follow up through emailfolder per palletainer - bin control-monthly inventory based on stock card record-Establish procedure for handling customer complaint
Production Manager
-Coordinate with FKC through GM in relation to the early submission of JOB Orders together with the drawings-Monthly physical inventory to be done to address inventory inaccuracy-additional manpower to support physical inventory and other QCD activities
Production Manager
Review of JO and drawing from Sales Department
No drawing received from Sales Department
delay in delivery/customer complaint
-Implementation of 5S and records management-Established standard procedure for control of documents-Signing of process owners who received the documents-follow up through emailfolder per palletainer - bin control-monthly inventory based on stock card record-Establish procedure for handling customer complaint
Production Manager
-Coordinate with FKC through GM in relation to the early submission of JOB Orders together with the drawings-Monthly physical inventory to be done to address inventory inaccuracy-additional manpower to support physical inventory and other QCD activities
Production Manager
0103 Production Planning Overlook Furukawa Kogyo's inventory Loss of customers 5 B MEDIUM ECA-PRD002
0104 Production Planning Copy of FKC's inventory is not updated 3 D MEDIUM ECA-PRD002
0105 Production Planning overlook on plant's inventory delayed delivery 3 C MEDIUM ECA-PRD003
0106 Production Planning Inaccurate inventory of valve parts delayed delivery 4 A MEDIUM ECA-PRD003
0107 Production Planning wrong specification of JO issued rejection of items 3 B MEDIUM ECA-PRD001
Review of inventory of items from Japan(Furukawa Kogyo)
-Establish procedure for handling customer complaint-Comply with summary of Job Orders (internal control)
Production Manager
Review of inventory of items from Japan(Furukawa Kogyo)
inaccurate forecasting of items needed
-Establish procedure for handling customer complaint-Comply with summary of Job Orders (internal control)
Production Manager
Review of inventory of items in the plant
-5S, established procedure for control of documents-established procedure for production planning-checking of inventory items-Established procedures for handling of customer complaints
Production Manager
-Monthly physical inventory to be done to address inventory inaccuracy-additional manpower to support physical inventory and other QCD activities
Production Manager
Review of inventory of items in the plant
-5S, established procedure for control of documents-established procedure for production planning-checking of inventory items-Established procedures for handling of customer complaints
Production Manager
-Monthly physical inventory to be done to address inventory inaccuracy-additional manpower to support physical inventory and other QCD activities
Production Manager
Ordering from subcontractor
-Implementation of 5S and records management-Established standard procedure for control of documents-Signing of process owners who received the documents-follow up through emailfolder per palletainer - bin control-monthly inventory based on stock card record-Establish procedure for handling customer complaint
Production Manager
0108 Production Planning late delivery Customer complaint 3 B MEDIUM ECA-PRD001
0109 Production Planning improper workload allocation high cost of inventory 5 B MEDIUM ECA-PRD004
0110 Production Planning improper workload allocation unable to meet target 3 B MEDIUM ECA-PRD004
0111 Production Planning delay in delivery 3 B MEDIUM ECA-PRD008
Ordering from subcontractor
-Implementation of 5S and records management-Established standard procedure for control of documents-Signing of process owners who received the documents-follow up through emailfolder per palletainer - bin control-monthly inventory based on stock card record-Establish procedure for handling customer complaint
Production Manager
Preparation of production requirement for the month (FDY & MCH)
-review distribution of workload-review of accomplished traceability slip-regular meeting with production personnel for weekly schedule-Proper review of JO-Established procedure on production planning
Production Manager
Preparation of production requirement for the month (FDY & MCH)
-review distribution of workload-review of accomplished traceability slip-regular meeting with production personnel for weekly schedule-Proper review of JO-Established procedure on production planning
Production Manager
Distributing schedule to Production Department
Headdelay in distribution of production requirements
-documented procedure in production planning-immediate endorsement of job order from sales-established procedure for handling of customer complaints
Production Manager
0112 Production Planning delay in production processes rejection of items 5 B MEDIUM ECA-PRD005
0113 Product status exposure to computer radiation Eye irritation/discomfort 3 c MEDIUM ECA-PRD006
0114 Wrong markings used rejection of item 4 C MEDIUM ECA-PRD007
0115 delayed issuance of pattern target output not met 3 C MEDIUM ECA-FDY024
0116 Urgent items not listed Delayed delivery 3 C MEDIUM ECA-FDY024
0117 Pattern records not updated internal rejection 2 D MEDIUM ECA-FDY024
Preparation of production schedule for shipping
-Review of JO-Inventory of casting-regular meeting with production personnel for weekly schedule of items-Established procedure for handling for customer complaints
Production Manager
Receipt and encoding daily production report
-Use different type of computer monitor-eye examination during APE-use of eyeglasses
Production Manager
Identification and Traceability
Attaching markings on pattern (pattern preparation)
-Issue JO and drawing to DND-Confirm markings and specifications vs. JO and Drawing-Regular production meeting-Established procedure and work instruction for pattern preparation and checking-Established procedure for customer complaints
Production Manager
Pattern and Corebox Preparation
Review of drawing and checking of pattern and corebox
-available drawings readily withdrawn from DND-Issuance of corrective and preventive action to concerned section
DND Head, Pattern
Supervisor
Pattern and Corebox Preparation
Review of drawing and checking of pattern and corebox
-available drawings readily withdrawn from DND-Issuance of corrective and preventive action to concerned section
DND Head, Pattern
Supervisor
Pattern and Corebox Preparation
Review of drawing and checking of pattern and corebox
-Check sheet history for provided to be filled up whenever the pattern undergoes repair-JO with specified changes on dimensions and markings are given to pattern supervisor-remelting of rejected items-issuance of corrective and preventive action to concerned section
DND Head, Pattern
Supervisor
0118 Workers might be hit by falling items injury/fatality 5 B MEDIUM ECA-FDY021
0119 Fire hazards in the pattern storage area loss of property and fatality 5 B MEDIUM ECA-FDY002
0120 Pattern repair Major injury 3 C MEDIUM ECA-FDY001
0121 Pattern repair Generation of waste (cut wood/saw dust) Air pollution(local) 3 C MEDIUM ECA-FDY028
Pattern and Corebox Preparation
Retrieval of drawing, pattern and corebox
-Preventive maintenance is conducted by maintenance department-Safety belt and ladder is used-availability of company clinic, nurse and trained first aiders
Pattern Supervisor
Pattern and Corebox Preparation
Retrieval of drawing, pattern and corebox
-Proper storage of reactive/flammable materials based on the study of MSDS - reactivity data and other related material properties-Availability of fire extinguisher and fire hydrant-formation of Fire Brigade and Emergency Team
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
Using and handling cutting tools(rip saw, band saw, etc.)
-Trade test conducted prior to hiring-Safety orientation required prior to work-Regular meeting is conducted(weekly and monthly)-Regular preventive maintenance-Providing PPEs to all workers-Long sleeve uniform provided to workers-established monitoring of busted lamps and immediate replacement-availability of company clinic, nurse and trained first aiders-employees are provided with health card
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
-utilization of annex area-dust collecting pan and container are provided-regular collection of saw dust and cut woods-issuance and usage of PPE
Pattern Supervisor,
Safety Committee
Consider installation of dust collection or exhaust duct to collect generated saw dust.
Pattern Supervisor,
Safety Committee, GM
0122 Pattern repair minor injury 3 C MEDIUM ECA-FDY039
0123 Pattern repair Penetration of foreign body to the eyes minor injury 2 D MEDIUM ECA-FDY003
Pattern and Corebox Preparation
Exposure to hazardous materials such as Araldite and Hardener
-Chemicals are place near window or open area for good ventilation-proper ppe is provided-available spill control materials and containment-orientation of concerned personnel on raw material MSDS-availability of company clinic, nurse and trained first aid team
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Pattern Supervisor,
Safety Committee
0124 Pattern repair Contact with sharp objects injury 3 C MEDIUM ECA-FDY001
0125 Failure to re-check pattern Rejection of casting 4 B MEDIUM ECA-FDY024
Pattern and Corebox Preparation
-Trade test conducted prior to hiring-Safety orientation required prior to work-Regular meeting is conducted(weekly and monthly)-Regular preventive maintenance-Providing PPEs to all workers-Long sleeve uniform provided to workers-established monitoring of busted lamps and immediate replacement-availability of company clinic, nurse and trained first aiders-employees are provided with health card
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
Checking of gating system, sprue pop-off, riser, markings, dowel
and wooden box
-Check sheet history for provided to be filled up whenever the pattern undergoes repair-procedure manual and work instructions are provided-JO with specified changes on dimensions and markings are given to pattern supervisor-remelting of rejected items-issuance of corrective and preventive action to concerned section
DND Head, Pattern
Supervisor
0126 Penetration of foreign body to the eyes minor injury 2 D MEDIUM ECA-FDY003
0127 Inhalation of odors/fumes by workers Respiratory illness 2 C MEDIUM ECA-FDY019
0128 Loss of property and fatality 5 B MEDIUM ECA-FDY002
0129 Accidental spillage of mold release agent Land contamination 3 C MEDIUM ECA-FDY018
0130 Delayed endorsement Delayed delivery to customer 4 C MEDIUM ECA-FDY025
Pattern and Corebox Preparation
Checking of gating system, sprue pop-off, riser, markings, dowel
and wooden box
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
Application of mold release agent
-use of respirator-regular air quality monitoring
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
Application of mold release agent
Presence of flame or fire near the working area
-Designated areas for mold release agent used in pattern repair-availability of fire extinguishers and fire hydrant-formation of Fire Brigade and Emergency Team
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
Application of mold release agent
-Awareness of the MSDS-Specific area for different material storage-materials are properly labeled-delivered in tin container--area for the material is contained-provision of spill kits
Pattern Supervisor,
Safety Committee
Pattern and Corebox Preparation
Endorsement of pattern to molding area
-established lead time/Production Schedule/Traceability Slip-Pattern inventory os provided
Pattern Supervisor, Producton Manager
-Outsourcing of other jobs not able to be accomodated by the patternmaking section-coordinate with customer for delivery date adjustment
Pattern Supervisor, Producton Manager
0131 Mold Preparation Incomplete parts or accessories Delay in production 3 C MEDIUM ECA-FDY031 Overtime utilizaton
0132 Mold Preparation struck by falling object Major injury 3 C MEDIUM ECA-FDY008
0133 Mold Preparation dropping of load from crane Major injury 3 C MEDIUM ECA-FDY008
0134 Mold Preparation crane overloading Major injury/crane damage 3 C MEDIUM ECA-FDY008
0135 Mold Preparation swinging of crane load Major injury 3 C MEDIUM ECA-FDY008
Checking completeness of pattern parts and accessories
-Pattern check sheet is accomplished prior to endorsement to molding-endorsement slip from pattern shop and casting traceability slip are accomplished and received accordingly by pattern and molding supervisors-casting traceability slip and monitoring sheet are issued to each process and accomplished
Molding Leadman,
Foundry Head, Producton Manager
Molding Leadman,
Foundry Head, Producton Manager
Preparation of molding boxesand/or reinforcement bars
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Molding Leadman,
Molder
Preparation of molding boxesand/or reinforcement bars
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Molding Leadman,
Molder
Preparation of molding boxesand/or reinforcement bars
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Molding Leadman,
Molder
Preparation of molding boxesand/or reinforcement bars
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Molding Leadman,
Molder
0136 Mold Preparation crane wheel falling off its rails Major injury 3 C MEDIUM ECA-FDY008
0137 Mold Preparation delay in production 3 C MEDIUM ECA-FDY045
0138 Mold Preparation Sanding operation use of chemicals costly 2 C MEDIUM ECA-FDY015
0139 Mold Preparation Sanding operation unpleasant surroundings 3 C MEDIUM ECA-FDY016
Preparation of molding boxesand/or reinforcement bars
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Molding Leadman,
Molder
Preparation of molding boxesand/or reinforcement bars
Shortage of molding boxes and/or reinforment bars
Traceability sheet issued to molders for the daily schedule of items to be moldedRescheduling of molding of items not able to be molded due to shortage
Production Manager,
Foundry Head, Molding Leadman
-Consider gathering data to help in efficient scheduling of items to be molded. Make an inventory of molding boxes and re-bars to serve as an aid during scheduling.-Fabricate new molding boxes/rebars
Production Manager,
Foundry Head, Molding
Leadman, Maintenance
-Performing calibration befor sanding operation-Panel control indicator lights up when the unit is malfunctioning-regular maintenance of dust collectors-WES Machine Daily Check Sheet is accomplised proir to operation-conttrol usage of chemical-installation of sand reclamation system
Molding Leadman,
Molder
Consider purchase of sieve analysis equipment to monitor and control sand grain size and adjust resin to sand ratio accordingly.
Foundry Engineer,
Purchasing, GM
Improper disposal of wastewater and wetted dust from dust collector
-Daily cleaning of wet-type dust collector-usage of metal container for wet dust collection-Use collected wet dust sa backfill
Molding Leadman,
Molder, Loader Operator
0140 Mold Preparation Sanding operation Improper calibration ratio 2 E MEDIUM ECA-FDY032
0141 Mold Preparation Sanding operation Foreign body contact with eyes minor injury 2 D MEDIUM ECA-FDY003
incompletely cured molds, rejected molds/castings
-Provide exclusive compressor unit for mixer-Conduct regular preventive maintenance on chemical pumps-Accomplish WES Machine Daily Check Sheet-Presence of Work Instruction at the work area-Regular addition of new sand-Replace reject
Molding Leadman, Molder,
Maintenance
Consider purchase of catalyst/resin blending machine that adjusts catalyst strength based on sand temperature in order to produce quality molds
Foundry Engineer,
Purchasing, GM
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Molding Leadman, Safety
Committee
0142 Mold Preparation Sanding operation Direct mixing and exposure to chemicals 4 B MEDIUM ECA-FDY019
0143 Mold Preparation Sanding operation minor injury 2 D MEDIUM ECA-FDY030
0144 Mold Preparation Sanding operation minor injury 2 D MEDIUM ECA-FDY036
Explosion/major injury/damage of company property
-Proper labeling of containers-Posting of work instruction at the sand calibration area-Chemical containers are located near the window for good ventilation-Proper PPE is provided-Spill response materials are available-containment-availability of company clinic , nurse and first aid team-health card is given to all regular employeesmaintenance of company property-availability of fire extinguisher at the work area-Issuance of PPE's
Molding Leadman, Safety
Committee
Person might fall down when stepping on roller conveyor
-Provision of stair step-5S program is implemented-implementation of 5S program-availability of company clinic-provision of health card for regular employees
Molding Leadman, Safety
CommitteeAvailability of hospital within 5km radius
Molding Leadman,
Safety Committee
Workers might be hit by hanging mixer when stepping on conveyor
-Discussing incidents during monthly safety meeting-Provision of stair step-Health card provided to each employee-Availability of company clinic-Trained first aider available on working area
Molding Leadman, Safety
Committee
0145 Mold Preparation Sanding operation minor injury 2 D MEDIUM ECA-FDY039
0146 Mold Preparation Sanding operation exposure to silica dust 3 C MEDIUM ECA-FDY039
0147 Mold Preparation Sanding operation exposure to silica dust lung injury (silicosis) 5 B MEDIUM ECA-FDY039
Skin, eye, respiratory & digestive tract irritation
-Chemical is placed near the window for good ventilation-Proper PPE is provided-available spill contrl materials and containment procedureorientation on concerned personnel on raw materials MSDS-availability of company clinic, nurse, and first aid team
Molding Leadman, Safety
Committee
minor injury (skin and eye irritation)
-Chemical is placed near the window for good ventilation-Proper PPE is provided-available spill contrl materials and containment procedureorientation on concerned personnel on raw materials MSDS-availability of company clinic, nurse, and first aid team
Molding Leadman, Safety
Committee
-Chemical is placed near the window for good ventilation-Proper PPE is provided-available spill contrl materials and containment procedureorientation on concerned personnel on raw materials MSDS-availability of company clinic, nurse, and first aid team
Molding Leadman, Safety
Committee
0148 Mold Preparation Ramming of sand mixture Foreign body contact with eyes minor injury(eye irritation) 2 D MEDIUM ECA-FDY003
0149 Mold Preparation Ramming of sand mixture soft ramming weak mold, casting rejection 2 E MEDIUM ECA-FDY032
0150 Mold Preparation body parts hit by mallet/hammer minor inury 2 C MEDIUM ECA-FDY042
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Molding Leadman, Safety
Committee
-Provide exclusive compressor unit for mixer-Conduct regular preventive maintenance on chemical pumps-Accomplish WES Machine Daily Check Sheet-Presence of Work Instruction at the work area-Regular addition of new sand-Replace reject
Molding Leadman, Molder,
Maintenance
Consider purchase of catalyst/resin blending machine that adjusts catalyst strength based on sand temperature in order to produce quality molds
Foundry Engineer,
Purchasing, GM
Curing and stripping of pattern/corebox and visual inspection
-maintaining safe distance from items for shakeout-established work instructions-modified handles from ball type to a more suitable and durable one-availability of company clinic, nurse and trained first aiders.
Molding Leadman,
Molder, Safety Committee
0151 Mold Preparation mold falls due to poor lifting technique minor injury 2 D MEDIUM ECA-FDY010
0152 Mold Preparation mold falls due to poor lifting technique molds rejected 2 D MEDIUM ECA-FDY010 Remolding
0153 Mold Preparation dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
Curing and stripping of pattern/corebox and visual inspection
-Crane operatoin seminar is given-Durable chain sling is used and with strength certificate provided-regular preventive maintenance of crane-daily checklist maintenance of crane-daily checklist of crane is accomplished prior to operation-PPE is provided-Availability of company clinic
Molding Leadman,
Molder, Safety Committee
Curing and stripping of pattern/corebox and visual inspection
-Crane operatoin seminar is given-Durable chain sling is used and with strength certificate provided-regular preventive maintenance of crane-daily checklist maintenance of crane-daily checklist of crane is accomplished prior to operation-PPE is provided
Molding Leadman,
Molder, Safety Committee
Molding Leadman,
Molder
Curing and stripping of pattern/corebox and visual inspection
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair-regular preventive maintenance of crane and forklift-checklist of crane prior to operation
Molding Leadman,
Molder
0154 Mold Preparation crane overloading Major injury/crane damage 3 C MEDIUM ECA-FDY008
0155 Mold Preparation swinging of crane load major injury 3 C MEDIUM ECA-FDY008
0156 Mold Preparation crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
Curing and stripping of pattern/corebox and visual inspection
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair-regular preventive maintenance of crane and forklift-checklist of crane prior to operation
Molding Leadman,
Molder
Curing and stripping of pattern/corebox and visual inspection
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair-regular preventive maintenance of crane and forklift-checklist of crane prior to operation
Molding Leadman,
Molder
Curing and stripping of pattern/corebox and visual inspection
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair-regular preventive maintenance of crane and forklift-checklist of crane prior to operation
Molding Leadman,
Molder
0157 Mold Preparation getting struck by forklift major injury 3 C MEDIUM ECA-FDY013
0158 Mold Preparation Foreign body contact with eyes minor injury 2 D MEDIUM ECA-FDY003
0159 Mold Preparation dropping hazard when lifting molds mold rejected 2 D MEDIUM ECA-FDY010 Remolding
Transfer of core molds to coating/setting area
-competency requirement for forklift operator and trade test is conducted-seminars and training on forklift safety operation-forklift horn, backing alarm and side mirrors are installed-regular preventive maintenance of forklift-forklift checksheet is accomplished daily by operator-painted gutters on the driveway
Molding Leadman,
Molder, Forklift Operator, Safety
Committee
-Conduct Forklift Training-Generate Forklift Training and certification program, plan and schedule-install necessary safety features of Forklift such as beacon light or blinkers
HR, Maintenance,
Safety Committee
Mold coating, drying and visual inspection
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Pattern Supervisor,
Safety Committee
Mold coating, drying and visual inspection
-Crane operatoin seminar is given-Durable chain sling is used and with strength certificate provided-regular preventive maintenance of crane-daily checklist maintenance of crane-daily checklist of crane is accomplished prior to operation-PPE is provided
Molding Leadman,
Molder, Safety Committee
Molding Leadman,
Molder
0160 Mold Preparation Alcohol catching fire and exploding major injury, fatality 5 C HIGH ECA-FDY022
0161 Mold Preparation minor injury 2 D MEDIUM ECA-FDY039
0162 Mold Preparation Ingestion of methanol fatality/blindness 5 B MEDIUM ECA-FDY040
Mold coating, drying and visual inspection
-Properly designated working areas as far away from the melting and pouring operations as possible-secure or cover the solution during the pouring process-Conduct monthly safety meeting-Availability of fire extinguishers and hydrants-formation of Fire Brigade and Response Team
Coating Operator,
Foundry Head/ Engineer, Safety
Committee
Mold coating, drying and visual inspection
Skin, eye, respiratory & digestive tract irritation
-Chemical is placed near the window for good ventilation-Proper PPE is provided-available spill control materials and containment procedureorientation on concerned personnel on raw materials MSDS-availability of company clinic, nurse, and first aid team
Coating Operator,
Foundry Head/ Engineer, Safety
Committee
Mold coating, drying and visual inspection
-orientation of concerned personnel on raw materials MSDS-wearing of provided PPE-chemicals are properly labeled
Coating Operator,
Foundry Head/ Engineer, Safety
Committee
0163 Mold Preparation Mold repair Foreign body contact with eyes minor injury 2 D MEDIUM ECA-FDY003
0164 Mold Preparation Mold repair collapse of repaired portion casting rejected 2 E MEDIUM ECA-FDY033
0165 Mold Preparation mismatch/loose clamping casting rejected 3 D MEDIUM ECA-FDY011
0166 Mold Preparation Mold might fall from crane mold rejected 2 D MEDIUM ECA-FDY010 Remolding
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Molding Leadman,
Maintenance, Safety
Committee
-presence of Work Instruction in work area-Presence of experienced supervisor and skiled line leader-presence of work instruction on sand calibration
Molding Leadman,
Foundry Head/ Engineer, Safety
Committee
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-On-job-training, orientation and close supervision-proper clamping of molds prior to transfer-ensure mold paste has dried prior to transfer-regular inventory of metal boxes and reinforcement bars
Setting Supervisor/
Operator
-Re-casting-discuss in production meeting for every major ocurrence
Foundry Head/ Engineer
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-Crane operatoin seminar is given-Durable chain sling is used and with strength certificate provided-regular preventive maintenance of crane-daily checklist maintenance of crane-daily checklist of crane is accomplished prior to operation-PPE is provided
Setting Supervisor/
Operator, Safety Committee
Molding Leadman,
Molder
0167 Mold Preparation Exposure to sparks and splashes minor injury (burns) 2 D MEDIUM ECA-FDY041
0168 Mold Preparation Alcohol catching fire and exploding major injury, fatality 5 C HIGH ECA-FDY022
0169 Mold Preparation minor injury 3 C MEDIUM ECA-FDY039
0170 Mold Preparation dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
0171 Mold Preparation crane overloading Major injury/crane damage 3 C MEDIUM ECA-FDY008
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-No mold re-touches by coating near furnace during charging operation-safety meeting and awareness-coating solution must be secured and no coating applications near the area during tapping and pouring
Setting Supervisor/
Operator
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
Skin, eye, respiratory & digestive tract irritation
-Chemicals are place near window or open area for good ventilation-proper ppe is provided-available spill control materials and containment-orientation of concerned personnel on raw material MSDS-availability of company clinic, nurse and trained first aid team
Setting Supervisor/
Operator
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/
Operator
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/
Operator
0172 Mold Preparation swinging of crane load major injury 3 C MEDIUM ECA-FDY008
0173 Mold Preparation crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
0174 Mold Preparation Receipt of mold assembly Wastage of electric power 3 D MEDIUM ECA-FDY017
0175 Mold Preparation Getting struck by forklift Major injury 3 C MEDIUM ECA-FDY013
0176 Mold Preparation Dust emission/smoke emission ill health/ air polution 2 C MEDIUM ECA-FDY019
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/
Operator
Mold assembly, endorsement of assembled molds to pouring and recording of poured molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/
Operator
Assembled molds are short of set target quantity
-accomplishment of casting traceability slip for each process.
Setting Supervisor/ Operator, Coating
Operator, Molder, Foundry Head/Engineer
Preparation of raw materials
-competency requirement for forklift operator and trade test is conducted-seminars and training on forklift safety operation-forklift horn, backing alarm and side mirrors are installed-regular preventive maintenance of forklift-forklift checksheet is accomplished daily by operator-painted gutters on the driveway
Forklift Operator, Safety
Committee
-Conduct Forklift Training-Generate Forklift Training and certification program, plan and schedule-install necessary safety features of Forklift such as beacon light or blinkers
HR, Maintenance,
Safety Committee
Preparation of raw materials
-use of respirator-regular air quality monitoring
Melting Leadman/
Operator, Safety Committee
0177 Mold Preparation Foreign body contact with eyes Minor injury 2 D MEDIUM ECA-FDY003
0178 Mold Preparation Metal charging Potential explosion Single to multiple fatality 5 B MEDIUM ECA-FDY026
0179 Mold Preparation Metal charging 5 B MEDIUM ECA-FDY004
Preparation of raw materials
-Trade test conducted prior to hiring-Safety orientation required prior to work-Regular meeting is conducted(weekly and monthly)-Regular preventive maintenance-Providing PPEs to all workers-Long sleeve uniform provided to workers-established monitoring of busted lamps and immediate replacement-availability of company clinic, nurse and trained first aiders-employees are provided with health card
Meltin g Leadman/
Operator, Safety Committee
-shaded scrap area to avoid wet metal charges-material segregation and presence of baling machine-accredited scrap supplier
Baling Operator, Purchasing , Warehouse,
Melting Leadman/ operator
Penetration of metal to cooling system causing explosion
Single to multiple fatality/ loss of property
-order lining materials only from accredited supplier-Operator on-the-job training-monitor number of heats per lining installation-built-in sensor on the furnace lining that can detect penetration-preventive maintenance conducted regulalry-electric furnace monitoring sheet is accomplished every charge-orientation of melting operator vis-a-vis furnace maintenance and operation
Melting Leadman/ Operator,
Mainenance Personnel,
Safety Committee
Presence of another furnace which can be used immediately
Melting Leadman/ Operator,
Foundry Head/ Engineer
0180 Mold Preparation Metal charging Use of electricity for the furnace 3 D MEDIUM ECA-FDY017
0181 Mold Preparation Metal charging Use of raw material(scrap) Depletion of resources 3 D MEDIUM ECA-FDY020
0182 Mold Preparation Metal charging Smoke emission (furnace) air pullution/ minor discomfort 2 C MEDIUM ECA-FDY019
Depletion of resources/ high production costs
-periodic preventive maintenance of furnaces-daily checksheet for electric furnace monitoring-skilled operator/ presence of work instruction-baled steel scrap to hasten cahrging and melting-accomplishment of casting traceability slip for each process.-preventive maintenance of crane and other machines-review of previous performance during Departmental Meeting-Continuous melting operation-monitoring kWh per kg of metal
Melting Leadman/ Operator,
Maintenance, Foundry
Head/Engineer
-production scheduling based on cutomer requirement and stock level-use of casting traceability slip-established cost reduction program through review of monthly inventory and consumption reports-recycling of metal splashes and fins-remelting of reject castings
Melting Leadman/ Operator, Foundry
Head/Engineer, Production Manager
-dust hood is installed-se of masks and respirators-regular air quality monitoring
Melting Leadman/ Operator,
Maintenance, Safety
Committee, Pollution Control
Officer
0183 Mold Preparation Metal charging Exposure to sparks and splashes Burns, minor injury 2 D MEDIUM ECA-FDY041
0184 Mold Preparation Metal charging dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
0185 Mold Preparation Metal charging swinging of crane load major injury 3 C MEDIUM ECA-FDY008
0186 Mold Preparation Metal charging crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Melting Leadman/ Operator
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Melting Leadman/ Operator
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Melting Leadman/ Operator
0187 Mold Preparation Metal charging Exposure to sparks and splashes Burns, minor injury 2 D MEDIUM ECA-FDY041
0188 Mold Preparation depletion of resources 3 D MEDIUM ECA-FDY017
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
Checking the composition of molten metal
Use of electricity for the furnace during holding time
-periodic preventive maintenance of furnaces-daily checksheet for electric furnace monitoring-skilled operator/ presence of work instruction-baled steel scrap to hasten cahrging and melting-accomplishment of casting traceability slip for each process.-preventive maintenance of crane and other machines-review of previous performance during Departmental Meeting-Continuous melting operation-monitoring kWh per kg of metal
Melting Leadman/ Operator,
Maintenance, Foundry
Head/Engineer
0189 Mold Preparation Exposure to sparks and splashes Burns, minor injury 2 D MEDIUM ECA-FDY041
0190 Mold Preparation Preheating of ladles Smoke emission air pollution 2 C MEDIUM ECA-FDY019
0191 Mold Preparation Preheating of ladles dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
0192 Mold Preparation Preheating of ladles swinging of crane load major injury 3 C MEDIUM ECA-FDY008
Checking the composition of molten metal
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
-dust hood is installed-se of masks and respirators-regular air quality monitoring
Melting Leadman/ Operator,
Maintenance, Safety
Committee, Pollution Control
Officer
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Melting Leadman/ Operator
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Melting Leadman/ Operator
0193 Mold Preparation Preheating of ladles crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
0194 Mold Preparation Chill testing Failure to conduct chill test hard casting 3 D MEDIUM ECA-FDY034 Replace rejected casting
0195 Mold Preparation Chill testing Exposure to sparks and splashes Burns, minor injury 2 D MEDIUM ECA-FDY041
0196 Mold Preparation Temperature checking Temperature too high 3 C MEDIUM ECA-FDY035
0197 Mold Preparation wrong sequence of chraging hard casting 3 D MEDIUM ECA-FDY034
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Melting Leadman/ Operator
-presence of work instruction in the working area
Melting Leadman/ Operator
Foundry Head/ Engineer
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
Wastage of resources and electricity
-Replace thermocouple-re-charge periodically-presenceof work instructoin and standard temperature-regular external calibratoin of pyrometer-orientation of concerned workers regarding the handling of pyrometer
Melting Leadman/
Operator, QC Inspector
-Switch off furnace power-Wait for temperatre to go down
Melting Leadman/ Operator,
Foundry Head/ Engineer
Charging of inoculant/ spheroidizer
Predsence of work instruction in the working area
Foundry Head/Engineer
0198 Mold Preparation Exposure to sparks and splashes Burns, minor injury 2 D MEDIUM ECA-FDY041
0199 Mold Preparation Metal spillage from the ladle Major injury 4 C MEDIUM ECA-FDY027
0200 Mold Preparation Exposure to sparks and splashes Burns, minor injury 2 D MEDIUM ECA-FDY041
Charging of inoculant/ spheroidizer
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
Tapping molten metal into the ladle
-provide in-house training for melter/pourer-regular claning and replacement of ladle lining
Melting Leadman/ Operator, Pouring
Operator
Tapping molten metal into the ladle
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
0201 Mold Preparation Molten metal runout from the mold 2 D MEDIUM ECA-FDY005
0202 Mold Preparation Ladle collapsing from crane Fatality 5 B MEDIUM ECA-FDY006
0203 Mold Preparation Pouring at high temperature Sand fusion, Rejected castings 3 C MEDIUM ECA-FDY035
Pouring molten metal into molds
temporary disability, rejected castings
-established work instructions to ensure consistent mold strength-correct and proper gating system-dowel dimension is checked-mold paste evaluated by QIT and approved for use-regular checking of flatness of molding boards-remelting of rejected castings-discussion on rejection included in weekly production meeting
Setting Supervisor/ Operator, Pouring
Operator, Foundry Head/
Engineer, Safety Committee
Pouring molten metal into molds
-awareness of cranes maximum capacity-ladle has different size according to capacity-regular preventive maintenance of crane-training on crane safety operation-checklist for crane prior to operation-issuance of work order to maintenance when abnormalities occur
Setting Supervisor/ Operator, Melting
Leadman/ Operator, Pouring
Operator, Foundry Head/
Engineer, Safety Committee
Pouring molten metal into molds
-Replace thermocouple-re-charge periodically-presenceof work instructoin and standard temperature-regular external calibratoin of pyrometer-orientation of concerned workers regarding the handling of pyrometer
Melting Leadman/
Operator, QC Inspector
Wait for temperature to go down
Pouring Operator,
Foundry Head/ Engineer
0204 Mold Preparation Rejected castings 3 D MEDIUM ECA-FDY007
0205 Mold Preparation dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
0206 Mold Preparation swinging of crane load major injury 3 C MEDIUM ECA-FDY008
0207 Mold Preparation crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
Pouring molten metal into molds
Pouring below the standard pouring temperature
-presence of work instructions on the work area-ladle preheating-checking and meeting required temperature before tapping-making multiple-cavity patternsfor small items-remelting-discussion on rejection included in weekly production meeting
Setting Supervisor,
Pouring Operator, Melting
Leadman/ Operator,
Foundry Head/ Engineer
Pouring molten metal into molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/ Operator, Pouring
Operator
Pouring molten metal into molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/ Operator, Pouring
Operator
Pouring molten metal into molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/ Operator, Pouring
Operator
0208 Mold Preparation Exposure to sparks and splashes Burns, minor injury 2 D MEDIUM ECA-FDY041
0209 Mold Preparation dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
0210 Mold Preparation swinging of crane load major injury 3 C MEDIUM ECA-FDY008
0211 Mold Preparation crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
0212 Mold Preparation Exposure to silica dust (refractory) silicosis 5 B MEDIUM ECA-FDY039
Pouring molten metal into molds
-provide cover for flow coat machine to be used during pouring-established work instruction for mold assembly which includes preheating of molds before setting-established work instruction for scrap press which includes safekeeping of prepared scrap-issuance of PPE (face shield, thermal gloves, apron - meters/pourers)-Availability of company clinic, nurse and trained first aiders
Setting Supervisor/ Operator, Pouring
Operator, Melting
Operator, Coating
Operator, Foundry Head/
Engineer, Safety Committee
Reject poor quality scrap pr returns that may cause splashing when charged
Melting Operator,
Foundry Head/ Engineer
Endorsement of poured molds to shakeout
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/ Operator, Pouring
Operator
Endorsement of poured molds to shakeout
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/ Operator, Pouring
Operator
Endorsement of poured molds to shakeout
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Setting Supervisor/ Operator, Pouring
Operator
Evaluating furnace condition
-provision of proper PPE-Orientation of concerned personnel on raw material MSDS
Foundry Head/Engineer,
Safety Committee
0213 Mold Preparation dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
0214 Mold Preparation swinging of crane load major injury 3 C MEDIUM ECA-FDY008
0215 Mold Preparation crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
0216 Mold Preparation crane overloading Major injury/crane damage 3 C MEDIUM ECA-FDY008
0217 Mold Preparation Exposure to silica dust (refractory) silicosis 5 B MEDIUM ECA-FDY039
0218 Mold Preparation Exposure to silica dust (refractory) minor injury 3 C MEDIUM ECA-FDY039
Receipt of poured molds and extraction of castings from molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Receipt of poured molds and extraction of castings from molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Receipt of poured molds and extraction of castings from molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Receipt of poured molds and extraction of castings from molds
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Receipt of poured molds and extraction of castings from molds
-provision of proper PPE-Orientation of concerned personnel on raw material MSDS
Foundry Head/Engineer,
Safety Committee
Receipt of poured molds and extraction of castings from molds
-provision of proper PPE-Orientation of concerned personnel on raw material MSDS
Foundry Head/Engineer,
Safety Committee
0219 Mold Preparation body parts hit by mallet/hammer minor injury 2 C MEDIUM ECA-FDY042
0220 Mold Preparation dropping of load from crane major injury 3 C MEDIUM ECA-FDY008
0221 Mold Preparation swinging of crane load major injury 3 C MEDIUM ECA-FDY008
0222 Mold Preparation crane wheel falling off its rails major injury 3 C MEDIUM ECA-FDY008
0223 Mold Preparation crane overloading Major injury/crane damage 3 C MEDIUM ECA-FDY008
0224 Mold Preparation Exposure to silica dust (refractory) minor injury 3 C MEDIUM ECA-FDY039
Receipt of poured molds and extraction of castings from molds
-maintaining safe distance from items for shakeout-established work instructions-modified handles from ball type to a more suitable and durable one-availability of company clinic, nurse and trained first aiders.
Molding Leadman,
Molder, Safety Committee
Removal of adhering sand from the castings
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Removal of adhering sand from the castings
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Removal of adhering sand from the castings
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Removal of adhering sand from the castings
-Height limit of storing molding boxes to approximately 5 ft.-Seminars on crane and forklift safety operation-inventory and cheking of molding box condition and subsequent repair
Shakeout Operator
Receipt of poured molds and extraction of castings from molds
-provision of proper PPE-Orientation of concerned personnel on raw material MSDS
Foundry Head/Engineer,
Safety Committee
0225 Shakeout and Cleaning Exposure to silica dust (refractory) lung injury (silicosis) 5 B MEDIUM ECA-FDY039
0226 Shakeout and Cleaning Foreign body contact with eyes minor injury 2 D MEDIUM ECA-FDY003
0227 Shakeout and Cleaning Finger hit by casting minor injury 2 C MEDIUM ECA-FDY042
0228 Shakeout and Cleaning minor injury 2 D MEDIUM ECA-FDY046
0229 Shakeout and Cleaning Dust and fume emission ill health/localized air pollution 2 D MEDIUM ECA-FDY012
Receipt of poured molds and extraction of castings from molds
-provision of proper PPE-Orientation of concerned personnel on raw material MSDS
Foundry Head/Engineer,
Safety Committee
Hammering off excess metal on the casting
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Shakeout Operator, Safety
Committee
Hammering off excess metal on the casting
-maintaining safe distance from items for shakeout-established work instructions-modified handles from ball type to a more suitable and durable one-availability of company clinic, nurse and trained first aiders.
Shakeout Operator, Safety
Committee
Hammering off excess metal on the casting
Body parts hit by chips or other casting parts during hammering
-Use of PPE to protect or minimize the force from flying objects
Shakeout Operator, Safety
Committee
-Consider use of hard plastic face shields for operators that perform hammering activities-establish safe distance that operators other than the one doing the hammering should be at during such activities-install dividers
Safety Committee
Transfer of sand/lumps to sand stock area and primary blasting
-preventive maintenance of machines-regular maintenance of dust collector-use of industrial fan-dust masks and earplugs are issued to employees-regular disposal of dust in the dust collector machine
Blastin Machine Operator,
Maintenance, Safety
Committee
0230 Shakeout and Cleaning Foreign body contact with eyes minor injury 3 C MEDIUM ECA-FDY003
0231 Shakeout and Cleaning minor injury 2 C MEDIUM
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Transfer of sand/lumps to sand stock area and primary blasting
-Adequate implementation of wearing PPE. Proper selection of PPE for different natures of work in the plant-Good Housekeeping program-Preventive maintenance of machines is done regularly-Installation of spray mist-Spraying of water on floor twice daily-installation of dividers at grinding area-availability of company clinic, nurse and first aid team
Blastin Machine Operator,
Maintenance, Safety
Committee
Transfer of sand/lumps to sand stock area and primary blasting
Slipping due to steel shot balls/ sand lumps on the floor
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