Name of organisation: LEIMRA PVT LTD
Site location: Indus Industrial Zone, AmadeUpCountry
Number of workers: 30 workers
General description of the organisation:
LEIMRA PVT LTD is a medium-sized manufacturing company specialising in the production of
precision metal components for the automobile and heavy machinery sectors. The facility
consists of a main production hall, welding and fabrication area, spray-paint booth, material
storage rooms, and packaging sections. Core activities include cutting, welding, grinding, spray-
painting, assembling, and packaging of products. Various machinery and equipment, including
lathe machines, overhead cranes, grinders, and spray booths, are used daily. The organisation
operates from 8am to 6pm, Monday to Friday, with staggered start and finish times to maintain
smooth workflow and reduce congestion on the shop floor.
Description of the area to be included in the risk assessment:
The scope of this risk assessment covers the main production hall, welding and fabrication areas,
spray-paint booth, and storage areas. The administrative offices have a separate risk assessment
in place.
Any other relevant information:
The Operations Director holds direct responsibility for health and safety and reports to the
Managing Director. Supervisors are appointed for each operational section and are responsible
for day-to-day safety monitoring in their respective areas.
Outline of how the risk assessment was carried out:
I began by reviewing relevant International Labour Organization (ILO) Codes of Practice and
British Health and Safety Executive (HSE) guidance, including “Health and Safety in
Engineering Workshops” and “Control of Substances Hazardous to Health (COSHH)”. A full
workplace inspection was conducted across all operational areas to identify visible hazards.
Consultations with workers provided additional insight into hazards not immediately apparent
during inspection, such as inadequate extraction for welding fumes. Accident records and
sickness absence data from the previous 12 months were reviewed to identify recurring issues.
Notes from inspections and consultations were then compared against industry guidance to
determine the adequacy of existing controls and to identify further actions required.
Organisation name: LEIMRA PVT LTD
Date of assessment: 8 August 2025
Scope of risk assessment: Main production hall, welding and fabrication area, spray-paint
booth, and storage areas
Hazard Who might be What are you What further Responsible
Timescales
category & harmed & already controls/actions are person’s job
(within…)
hazard how? doing? required? title
Welders and
General Install Local Exhaust
nearby workers
ventilation in Ventilation (LEV) at
– Inhalation
Hazardous welding area; all welding stations;
could cause
substances – basic Provide respirators
occupational
Welding disposable with P3 filters; Operations
asthma, metal 3 months
fumes masks Introduce health Director
fume fever,
(containing provided; surveillance for
long-term lung
metal oxides) welding welders; Train
damage; eye
screens in workers on correct
irritation from
place PPE use
UV light
Machine Install
operators – fixed/interlocked
Machinery
Entanglement Basic training machine guards; Fit
hazards –
causing cuts, provided; “Do emergency stop
Unguarded Maintenance
fractures, or not operate buttons; Implement 1 month
rotating parts Manager
amputations; without guard” lock-out/tag-out
on lathe
maintenance signage procedure; Refresher
machines
workers at risk training for all
during repairs operators
Provide mechanical
Manual Some trolleys
lifting aids (hoists);
handling – Fabrication available;
Manual handling
Lifting heavy workers – Back workers Stores
training; Redesign 2 months
metal sheets injuries, muscle advised to seek Supervisor
storage layout to
and strains, hernias help for heavy
minimise lifting
components lifts
distances
Workshop
Conduct full noise
Noise – workers –
Earplugs survey; Install
Continuous Noise-Induced
issued; noisy acoustic barriers;
grinding, Hearing Loss
equipment Enforce mandatory 4 months HSE Officer
hammering, (NIHL); stress
maintained hearing protection;
and machine and fatigue from
regularly Health surveillance
operation prolonged noise
for hearing
exposure
Slips & trips – All workers and Walkways Weekly floor 1 month Workshop
Oil spills, visitors – Cuts, marked; spill degreasing; Random Supervisor
scattered bruises, kits available; housekeeping
metal scraps, fractures, sprains designated inspections; Provide
trailing cables waste bins additional floor bins
for metal waste;
Install extra sockets
to reduce trailing
Hazard Who might be What are you What further Responsible
Timescales
category & harmed & already controls/actions are person’s job
(within…)
hazard how? doing? required? title
cables
Work at Harnesses Develop Safe 1 month
height – available; System of Work
Maintenance
Maintenance ladders (SSoW); Install
staff – Falls Maintenance
on overhead inspected; temporary edge
causing serious Manager
cranes and work at height protection; Provide
injury or death
high only when refresher training for
platforms authorised working at height
Install automatic fire
suppression in paint
Fire & Fire booth; Store
explosion – extinguishers flammables in fire-
All personnel –
Flammable installed; Fire rated cabinets;
Burns, smoke Operations
paints, drills twice Update fire risk 2 months
inhalation, Director
solvents, and yearly; basic assessment; Ensure
fatalities
welding paint booth all welding near
sparks ventilation flammables is
authorised under hot
work permit
Replace damaged
Electrical leads; Install more
hazards – Annual PAT fixed sockets;
All staff –
Damaged testing; main Conduct electrical
Electric shock, Electrical
extension switchboard safety toolbox talk; 1 month
burns; potential Supervisor
leads and has RCD Implement quarterly
fire
overloaded protection inspection of
sockets portable electrical
equipment
Operators –
Vibration –
Hand-Arm Low-vibration Monitor usage time;
Use of
Vibration tools Implement job
grinders,
Syndrome purchased; rotation; Introduce
impact 3 months HSE Officer
(HAVS); equipment HAVS health
wrenches, and
numbness and maintained surveillance; Provide
other power
circulation regularly anti-vibration gloves
tools
problems
Hazardous Paint booth All spraying in Repaint clearance 2 months Paint Shop
substances – operators – enclosed time signage; Supervisor
Spray-paint Inhalation can booth; air-fed Introduce quarterly
solvents cause masks ventilation
(isocyanates) occupational provided; performance checks;
asthma; skin ventilation Health surveillance
contact may system for spray operators;
Hazard Who might be What are you What further Responsible
Timescales
category & harmed & already controls/actions are person’s job
(within…)
hazard how? doing? required? title
serviced PPE training
cause dermatitis
annually refresher
Moral, General Legal and Financial Arguments for ALL Actions
LEIMRA PVT LTD has a clear moral duty to protect all its workers from foreseeable risks to
their health and safety. Employees attend work to earn a living and should not be exposed to
conditions that could result in injury, illness, or even death. Some hazards in the manufacturing
environment — such as welding fumes, unguarded machinery, and flammable paint vapours —
have the potential to cause life-changing harm or long-term health conditions, including
respiratory disease, amputations, or severe burns. Witnessing such incidents can also cause
psychological harm to co-workers.
From a legal perspective, the company must comply with ILO Convention C155 and related
Recommendations (R164), which require employers to ensure that workplaces, equipment, and
systems of work are safe and without risks to health. National legislation based on these
conventions further reinforces the duty to eliminate or control workplace hazards. Specific
requirements also exist under COSHH regulations for hazardous substances, and machinery
safety regulations for guarding and maintenance.
Financially, workplace incidents can have significant consequences. Direct costs include sick
pay, compensation claims, equipment repairs, and lost production time. Indirect costs, which are
often higher, include legal fees, increased insurance premiums, regulatory penalties, reputational
damage, and potential loss of contracts. Enforcement action by regulators could lead to
improvement or prohibition notices, temporarily stopping certain operations and affecting
business continuity.
By addressing these hazards proactively, LEIMRA PVT LTD can protect its workforce, comply
with the law, and maintain its operational and financial stability.
Action 1 – Install Local Exhaust Ventilation (LEV) for Welding Fumes
Specific legal arguments:
ILO’s Safety in the Use of Chemicals at Work Code of Practice and COSHH regulations require
employers to prevent or control exposure to hazardous substances by engineering means
wherever reasonably practicable. LEV is a recognised method for controlling fumes at source.
Likelihood and severity:
Welding is carried out daily by eight workers, with others nearby exposed to secondary fumes.
Likelihood of inhalation without effective extraction is high. Severity ranges from “major”
(chronic respiratory illness) to “catastrophic” (fatal occupational disease).
Effectiveness:
Installing LEV at each welding station will capture contaminants before they reach the breathing
zone. This will greatly reduce airborne concentrations, protecting workers and improving air
quality throughout the workshop. The 3-month timescale allows for specification, procurement,
and installation.
Action 2 – Install Fixed/Interlocked Guards on Lathe Machines
Specific legal arguments:
ILO Recommendation R164 and national machinery safety regulations require that moving parts
of machinery be guarded to prevent access during operation. Interlocked guards ensure machines
cannot operate unless the guard is in place.
Likelihood and severity:
Lathe operations occur daily, with five trained operators. Contact with unguarded rotating parts
could cause amputations or severe lacerations, making the severity “major”. Likelihood is
moderate to high given regular use and potential for operator distraction.
Effectiveness:
Interlocked guards will prevent operators from coming into contact with moving parts during
operation. Emergency stop buttons will provide an additional level of safety. A 1-month
timeframe is realistic as guards are commercially available and installation is straightforward.
Action 3 – Install Automatic Fire Suppression System in Paint Booth
Specific legal arguments:
ILO’s Prevention of Major Industrial Accidents Code of Practice and fire safety regulations
require suitable prevention and mitigation measures for areas where flammable vapours are
present.
Likelihood and severity:
Paint spraying is carried out daily using solvent-based paints containing isocyanates. Ignition
sources include welding operations and static discharge. While likelihood of ignition is moderate
with current controls, the severity of an incident is “catastrophic”, potentially causing multiple
fatalities and major property damage.
Effectiveness:
An automatic suppression system will detect and extinguish fires in the early stages, preventing
escalation and reducing the risk of injury, fatalities, and significant damage. A 2-month timescale
allows for design, installation, and testing without disrupting production schedules.
Planned review date/period and reasoning:
In line with LEIMRA PVT LTD’s health and safety policy, all risk assessments will be formally
reviewed every 12 months. However, earlier reviews will be carried out if there is a significant
change in work processes, introduction of new machinery or substances, or following a major
incident. This approach ensures that the risk assessment remains relevant and that any new or
emerging hazards are identified and controlled promptly. The next scheduled review date for this
assessment is 8 August 2026.
How the risk assessment findings will be communicated and who needs to know the
information:
The Operations Director will first review and approve the findings. Once approved, the HSE
Officer will distribute a summary of the assessment and action plan to all relevant department
supervisors, including the Workshop Supervisor, Maintenance Manager, Paint Shop Supervisor,
and Stores Supervisor. This will be done via email for record-keeping and followed up by face-
to-face briefings where necessary. The findings and specific actions will be communicated to all
workers during toolbox talks, ensuring they understand the hazards, existing controls, and any
changes to working procedures. Visual summaries will be posted on the workshop notice boards
and made available on the company intranet for ongoing access by all staff. Contractors who
work on-site will also be provided with relevant parts of the risk assessment during their site
induction.
How follow-up on the risk assessment will be carried out:
A tracking system will be established using the company’s safety management software. Each
action will be assigned to a responsible person and given a due date. The HSE Officer will set
reminders for 10 days before each deadline to check progress with the responsible person. If an
action is delayed, the reason will be investigated — for example, financial constraints, supplier
delays, or lack of resources. Where necessary, the Operations Director will be asked to allocate
additional resources to ensure timely completion. Actions that are more than three months
overdue will be escalated to the Managing Director. Follow-up inspections will confirm that
completed actions have been implemented effectively and are functioning as intended.