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Risk Register Risk Area/Process Activity Identified Risk Scenario Impact Overall Risk Reference Contingency Action(s) Severity Likelihood Risk Level 0001 business loss 5 C HIGH ECA-OGM001 OGM 0002 Budgeting Unavailable data 3 C MEDIUM ECA-OGM002 OGM 0003 Budgeting 5 D HIGH ECA-OGM003 OGM 0004 Budgeting 5 D HIGH ECA-OGM003 OGM 0005 Budgeting miscalculation 5 D HIGH ECA-OGM003 OGM 0006 Budgeting misinterpretation/miscalculation 5 D HIGH ECA-OGM003 OGM 0007 Budgeting delay in reviewing budget drafts 5 D HIGH ECA-OGM003 OGM 0008 Budgeting miscalculation 5 D HIGH ECA-OGM003 OGM 0009 Budgeting miscalculation 5 D HIGH ECA-OGM003 OGM 0010 Budgeting disapproval 5 D HIGH ECA-OGM003 OGM 0011 Budgeting discrepancy in budget figures 5 D HIGH ECA-OGM003 OGM 0012 Budgeting inaccurate data business loss 5 D HIGH ECA-OGM003 OGM 0013 Budgeting inappropriate analysis 5 D HIGH ECA-OGM003 OGM 0014 occurrence of incident 5 B MEDIUM ECA-EHS001 IMR 0015 3 B MEDIUM ECA-EHS004 IMR IMR Risk Register # Prevention/ Mitigation Action(s) Person-in- charge Person-in- charge Office of the General Manager Assessment, deployment, implementation, review, and adjustment phase of SBPP failure to conduct effective strategic business plan 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 -double time in preparing the budget -rescheduling of the activity Setting goals and targets Setting of unrealistic goals and targets misappropriation of resources review action plans and variances Dissemination of goals and target misinterpretation of goals and targets misappropriation of resources review action plans and variances Formulation of action plans and budget misappropriation of resources review action plans and variances Review of action plans and budget misappropriation of resources review action plans and variances Review of action plans and budget misappropriation of resources review action plans and variances Revision of budget drafts misappropriation of resources review action plans and variances Review of budget drafts and preparation of master budget misappropriation of resources review action plans and variances Presentation to President for approval delay in performing projected activity review action plans and variances Revision of master budget draft misappropriation of resources review action plans and variances Monitoring performance review action plans and variances Conducting corrective/preventive action recurrence of problem/business loss review action plans and variances Hazard/Aspect Identification and Risk Assessment Identification of occupational health and safety hazards/environmental aspects per activity failure to indentify certain hazard/impact Choose group of skilled/trained assessor in conducting assessment for brainstorming 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 FM-RSK004 Rev. 00

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Sample Risk Register Form for API Documentation

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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

0232023302340235023602370238023902400241024202430244024502460247024802490250025102520253025402550256025702580259026002610262026302640265026602670268

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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