Agent skill

Healthsafety

UK health and safety management for manufacturing operations. Covers risk assessments, COSHH, PPE, incident reporting, LOTO, manual handling, and emergency procedures. Aligned with UK HSE regulations and IATF 16949 clause 7.1.4. USE WHEN user says 'health and safety', 'risk assessment', 'COSHH', 'PPE', 'accident', 'incident', 'LOTO', 'lockout tagout', 'manual handling', 'emergency procedure', or needs safety compliance guidance.

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SKILL.md

HealthSafety

UK health and safety management for MNMUK manufacturing operations, aligned with the Health and Safety at Work Act 1974, UK HSE regulations, and IATF 16949.

Workflow Routing

Workflow Trigger File
RiskAssessment "risk assessment", "hazard assessment" Workflows/RiskAssessment.md
IncidentReporting "accident", "incident", "near miss" Workflows/IncidentReporting.md
CoshhAssessment "COSHH", "chemical", "hazardous substance" Workflows/CoshhAssessment.md
SafetyAudit "safety audit", "inspection" Workflows/SafetyAudit.md

Legal Framework (UK)

Primary Legislation

Act/Regulation Requirement MNMUK Application
Health and Safety at Work Act 1974 General duty of care Foundation of all H&S
Management of Health and Safety at Work Regulations 1999 Risk assessment, competent persons Risk assessment programme
COSHH Regulations 2002 Control of hazardous substances Chemical management
PUWER 1998 Provision and use of work equipment Machine safety
Manual Handling Operations Regulations 1992 Reduce manual handling risks Lifting assessments
PPE at Work Regulations 1992 Provide appropriate PPE PPE programme
RIDDOR 2013 Report specified injuries/incidents Incident reporting

Enforcement

Body Role
Health and Safety Executive (HSE) Primary enforcement authority
Local Authority Certain workplace types
Environment Agency Environmental hazards

IATF 16949 Alignment

IATF Clause Requirement H&S Coverage
7.1.4 Environment for operation Physical, psychological, social factors
7.1.4.1 Cleanliness of premises Housekeeping, 5S, safety
8.5.1.5 Total productive maintenance Equipment safety maintenance
7.2 Competence H&S training requirements

Reference: ~/projects/work/docs/work-instructions/procedures/hr/HRP-004_Health_Safety.md

Risk Assessment Framework

UK HSE 5-Step Methodology

All risk assessments at MNMUK must follow the UK HSE 5-step methodology:

Step HSE Step Description
1 Identify the hazards Walk the area, consult workers, review SDS/accident history, consider non-routine tasks
2 Decide who might be harmed and how Employees, contractors, visitors, vulnerable persons; identify exposure routes
3 Evaluate the risks and decide on precautions Consider existing controls, apply hierarchy of control, use risk matrix to prioritise
4 Record your findings and implement them Document hazards, persons at risk, existing and additional controls; assign actions with owners and dates
5 Review your assessment and update if necessary Review after incidents, process changes, or at least annually

Hazard Categories

Category Examples Assessment Approach
Mechanical Moving parts, nip points, ejection Machine-specific assessment
Chemical Coolants, solvents, oils COSHH assessment
Physical Noise, vibration, temperature Environmental monitoring
Ergonomic Repetitive motion, posture, lifting Workstation assessment
Electrical Shock, arc flash Electrical safety programme

Risk Matrix (Step 3)

PPE Requirements

PPE by Area

Area Minimum PPE Additional as Required
Manufacturing floor Safety glasses, safety footwear Hearing protection
Machine operation + Hearing protection Face shield for grinding
Chemical handling + Chemical-resistant gloves Face shield, apron
Welding areas Welding helmet, leather gloves Fire-resistant clothing
Overhead work Hard hat Fall protection

PPE Management

Requirement Frequency
Issue and record At hire / as needed
Condition inspection Daily by user
Replacement When damaged or worn
Training on use At issue

Machine Safety

Key Requirements (PUWER)

Requirement Standard
Guarding All nip points, moving parts guarded
Interlocks Guards interlocked where practical
Emergency stops Accessible within reach
Maintenance Safe systems, isolation

Lockout/Tagout (LOTO)

8-Step LOTO Procedure:

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

Energy Types:

  • Electrical
  • Pneumatic
  • Hydraulic
  • Mechanical (springs, gravity)
  • Thermal
  • Chemical

COSHH Management

Hazardous Substances at MNMUK

Category Examples Controls
Cutting fluids Coolants, neat oils LEV, PPE, skin care
Cleaning solvents Degreasers, IPA Ventilation, PPE
Lubricants Oils, greases Skin protection
Welding fumes Metal fumes LEV, respiratory protection

COSHH Requirements

Requirement Action
Assessment For each substance/process
Control measures Hierarchy of controls
Health surveillance Where required by assessment
Information/training All exposed employees
SDS availability At point of use

Manual Handling

Assessment Triggers

Factor Assessment Required
Weight >10kg regular handling
Frequency Repeated lifting
Posture Twisting, bending, reaching
Environment Space constraints
Individual Known conditions

Control Hierarchy

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

Incident Management

Reportable Incidents (RIDDOR)

Category Examples Reporting
Fatal Any workplace death Immediate
Specified injuries Fractures, amputations, loss of sight Within 10 days
Over 7-day incapacitation Unable to work >7 days Within 15 days
Occupational diseases As specified in RIDDOR When diagnosed
Dangerous occurrences Near misses as specified Within 10 days

Investigation Process

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

Emergency Procedures

Emergency Types

Emergency Response
Fire Alarm, evacuate, assemble, account
Medical First aid, call 999, assist responders
Chemical spill Evacuate area, contain if safe, notify
Gas leak Evacuate, no ignition sources, notify

Emergency Equipment

Equipment Location Inspection
Fire extinguishers Throughout facility Monthly visual, annual service
First aid kits Each department Monthly check
AED Main entrance, production Monthly check
Eye wash stations Chemical areas Weekly flush
Spill kits Chemical storage, machines Monthly check

Drill Schedule

Drill Frequency
Fire evacuation Quarterly
First aid response Annual
Chemical spill Annual

Safety Training

Training Matrix

Training Who When Refresher
General safety induction All employees At hire Annual
Job-specific hazards Affected employees At assignment As needed
PPE use All employees At hire/issue As needed
LOTO Authorized personnel Initial Annual
First aid Designated responders Initial Biennial
Fire warden Designated wardens Initial Annual
Forklift/MHE Operators Initial Triennial
COSHH Exposed employees At assignment Annual

Safety Audits

Audit Programme

Audit Type Frequency Scope
Department inspection Weekly Area-specific hazards
Safety committee Monthly Rotating areas
Management review Quarterly Programme effectiveness
External audit Annual Full compliance

Audit Focus Areas

  • Housekeeping and 5S
  • PPE compliance
  • Machine guarding
  • Chemical storage
  • Emergency equipment
  • Documentation currency

Performance Metrics

Metric Target Frequency
Recordable incident rate <2.0 Monthly
Lost time incident rate <1.0 Monthly
Near miss reports >5/month Monthly
Training completion 100% Monthly
Audit score >90% Monthly
Open actions <5 overdue Weekly

Record Retention

Record Retention Period
Risk assessments 3 years (or while valid)
Training records Employment + 7 years
Incident reports 10 years
RIDDOR reports 10 years
COSHH assessments 40 years
Health surveillance 40 years
Audit records 3 years

Integration with Other Skills

Skill Integration Point
AutomotiveManufacturing Process safety in procedures
Pfmea Safety failure modes
Assemblyoperations Assembly-specific hazards
Maintenancepm Equipment safety checks
Tribalknowledge Safety practices capture

Examples

Example 1: New machine installation

User: "We're installing a new CNC lathe"
→ Conduct risk assessment (Workflows/RiskAssessment.md)
→ Verify guarding per PUWER
→ Develop LOTO procedure
→ Train operators
→ Update department risk assessment

Example 2: Chemical spill incident

User: "We had a coolant spill in Machine Shop"
→ Ensure immediate response complete
→ Complete incident report (Workflows/IncidentReporting.md)
→ Investigate root cause
→ Review COSHH assessment
→ Implement corrective actions

Example 3: New substance introduction

User: "We want to use a new degreaser"
→ Obtain SDS from supplier
→ Conduct COSHH assessment (Workflows/CoshhAssessment.md)
→ Determine controls required
→ Train affected employees
→ Update chemical register

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