SOP for Risk-Based Unsafe Condition Tagging System
Document No.: MTL-PE-HSE-SOP-UC001 Effective Date: January 01, 2026
Approved By: HOD HR & Admin (HSE)
1. Purpose
To establish a risk-based visual tagging system for identifying, communicating, and controlling
unsafe conditions observed during routine HSE surveys, ensuring timely corrective actions,
accountability, and continuous improvement in occupational health and safety performance.
2. Scope
This SOP applies on all machines, equipment, work areas, locations, and processes within the MTL-
PE where unsafe conditions are identified during:
Monthly HSE surveys
Routine inspections/Survey/Visit
Incident investigations
3. References
ISO 45001:2018 (Clauses 6.1, 7.4, 8.1)
ISO 31010: Risk Assessment Techniques
HSE-UK: HSG65 & INDG163
OSHA 29 CFR 1910.145 (Safety Signs & Tags)
Punjab Occupational Safety & Health Act, 2019
Factories Act, 1934
4. Definitions
Unsafe Condition: A physical or environmental condition that may cause injury, ill health, or
damage.
Risk Rating: Calculated as Severity × Likelihood using the standard’s* risk matrix.
Tag: A physical label affixed at the point of hazard to visually communicate risk and
responsibility (annex 1).
5. Tag Colour Coding (Based on Risk Matrix)
Risk Level Colour Action Requirement
High (16–25) Red Immediate action / stop work if required
Medium (8–15) 🟠 Orange Corrective action within defined timeframe
Low (1–7) 🟢 Yellow Monitor and improve
6. Tag Information (Mandatory)
Each tag shall clearly display:
Location / Machine No.
Description of unsafe condition
Risk level (color-coded)
Responsible person / department
Highlighted by (HSE / Name)
Date of observation
Target closure date
Tag ID / Reference No.
7. Procedure
1. Identification
o Unsafe conditions shall be identified during monthly HSE surveys, inspections, or
routine visit
2. Risk Assessment
o Risk should be evaluated using the standard’s* risk matrix (Severity × Likelihood).
3. Tagging
o Appropriate color-coded tag shall be affixed at the exact location or machine where
the unsafe condition exists.
4. Responsibility Assignment
o Concerned department or responsible person shall be clearly mentioned on the tag.
5. Corrective Action
o Responsible person shall initiate corrective actions within the defined timeframe
based on risk level.
6. Verification & Closure
o HSE verifies corrective action.
o Tag will be removed only by HSE executives.
o Status will be updated in the HSE survey record.
8. Roles & Responsibilities
HSE Department
Conduct surveys and risk assessments
Issue and track tags
Verify corrective actions
Department Heads / Managers / Supervisors
Ensure timely corrective actions
Allocate resources
Prevent recurrence
Employees
Follow tag instructions
Do not remove tags without authorization
9. Records
All records shall be maintained by HSE and present in monthly DCM-HSE
* The organization applies a 1–5 likelihood and 1–5 severity qualitative risk scoring methodology,
which is not derived from a single prescriptive standard but is an industry-accepted practice. ISO
31010 does not define fixed numerical scales and allows organizations to establish risk criteria
suitable to their operational context. Accordingly, the 5×5 risk matrix has been developed in
alignment with ISO 31000 risk management principles and is supported by guidance and good
practices from HSE-UK, OSHA, ANSI Z690, and NEBOSH risk assessment methodologies.
Annexure 1 Tag Format:
Prepared by Approved by
____________________________ _______________________
Manager IR & HSE HOD HR & Admin (HSE)