ISO 45001 Implementation – A Case Study on Implementing Workplace Hazard and Risk Management in Manufacturing Industry

24/08/2022by admin0Read: 7 minutes

Proper ISO 45001 implementation and effective occupational health and safety management are essential for the manufacturing industry due to the various hazards it faces.

ISO 45001 standard allows the creation of an Occupational Health and Safety Management System that can be customised for the manufacturing sector.

Our Case study on Implementing Workplace Hazard and Risk Management in the Manufacturing industry can help you understand the types of hazards faced and robust solutions to overcome them by effective ISO 45001 Implementation.

Workplace Hazards in Manufacturing Industry that need to be taken seriously

Here are some common yet important workplace hazards in the manufacturing industry that need to be addressed for efficient risk management and workers’ health and safety:

1) Housekeeping

ISO 45001 Implementation - Housekeeping

Poor housekeeping can contribute to incidents like:

  • Being hit by falling objects, or tripping over loose objects on floors, stairs, and platforms.
  • Slipping on slippery, wet, or dirty surfaces.
  • Bumping into protruding, haphazardly stacked, misplaced objects.
  • Tearing, cutting, or puncturing the skin of one’s hands or other body parts on protruding nails, wire, or steel strapping.

A manufacturing workplace must ‘maintain’ order throughout a workday to avoid these risks. Even though this effort necessitates extensive management and planning, there are numerous advantages.

2) Food and drink

Employees working in the food industry are exposed to a variety of biological and chemical risks, including infectious diseases, working with dust (found in grains, for example), and disinfectants. A worker may suffer from respiratory issues, skin conditions, or become generally ill, which can have a negative impact.

3) Repurposed food and drink packaging

The use of repurposed food and drink packaging increases potential sources of contamination and frequently also the quantities and concentrations of chemicals that can leach from the packaging into foods, possibly posing a threat to human health. Non-permanent materials like paper and plastic can undergo a change in their state after undergoing recycling, and their new form can react with food packed in them ad thus contaminate it.

4) Inadequate guarding of plant/equipment

ISO 45001 Implementation - Inadequate guarding of plant/equipment
Inadequate guarding of plant/equipment

Inadequate guarding of plants or equipment can lead to serious life-threatening injuries. Multiple injuries can be caused by moving machinery: Machinery moving parts or projectiles can strike and injure people. Additionally, body parts may be trapped between pulley drives, belts, and rollers.

5) Objects on the floor and walkway

ISO 45001 Implementation - Objects on the floor and walkway
Objects on the floor and walkway

Objects kept or fallen on the floor and walkway can lead to falling, tripping or injury etc., as workers might mistakenly fall due to the road blockages. Furthermore, cluttered places are demotivating, and hence manufacturing companies should keep floors and walkways clear of any objects.

6) Obstructions on Keep clear area

ISO 45001 Implementation - Obstructions on Keep Clear
Obstructions on Keep Clear

Obstructions on Keep Clear areas like aisles, walkways, fire exits, emergency exits, and storage areas can lead to severe hazards during an emergency. These areas are significant and need to be clear of any obstruction to prevent any hazard.

7) Spillage

ISO 45001 Implementation - Spillage

It can include chemical or water spillage that can lead to falls, slips or trips. Spillage can lead to improperly maintained machinery.

8) Electrical

ISO 45001 Implementation - Electrical Wire fallen on floor
Electrical Wire fallen on floor

Electrical shocks are a workplace health and safety hazard that can have a minor or severe effect on the workforce.

9) Gas Cylinders

Gas Cylinders
Gas Cylinders

Sprains, strains, falls, bruises, and broken bones may occur as a result of the careless handling of gas cylinders. Other dangers include fire, explosion, chemical burns, etc.

10) Psychosocial Hazards

ISO 45001 Implementation - Psychosocial Hazards
Psychosocial Hazards

These include work stress, work pressure, or stress caused while handling equipment.

How to Overcome Workplace hazards in Manufacturing Industry?

  1. Implementing effective housekeeping practices.
  2. Keeping floors, staircase, emergency exits etc., clear, and free of any obtrusion.
  3. Properly handling gas cylinders.
  4. Regularly maintaining equipment and machinery can enhance its shelf life and prevent spillage.
  5. Employees must wear protective suits and necessary gear to protect them from dust noise, bacteria etc.
  6. Manufacturing industries must regularly check and maintain electric wires, switchboards, etc.
  7. Employee interaction and counselling can help in understanding psychosocial hazards faced by workers. This can help overcome workplace stress and promote the mental well-being of employees.
  8. Prevent non-permanent materials in recycling or use them in the packaging of foods that might not undergo contamination.

Steps to ISO 45001 Implementation at Manufacturing Industries for effective Hazards and Risk Management

ISO 45001 Standard is written to be tailored according to any industry’s requirement, and the manufacturing industry can greatly benefit from it.

In this section, we will discuss the essential steps a manufacturing industry must take to implement ISO 45001 Standard effectively:

1) Setting Goals and Focus

Setting Goals
Setting Goals

The very first step shall be of defining your manufacturing company’s goals and area of focus. The management plays a key role in this process.

2) Audit to Analyse Hazards


In the next step, the organisation must do a survey to know and analyse the various hazards affecting workers’ health in the manufacturing factory.

3) Documenting Risks and their Consequences

ISO 45001 Implementation – Documentation

Documenting the various health and safety risks and their consequences is essential. It can be used to compare the status of the various risks after the successful ISO 45001 implementation.

4) Gap Analysis

Gap Analysis
ISO 45001 Implementation – Gap Analysis

A Gap analysis audit will help in understanding the areas where a company is falling short in terms of the various hazards mentioned above. It will help in creating a plan to overcome the risks faced by workers.

5) Formulating ISO 45001 strategy

5)Formulating ISO 45001 strategy
Formulating ISO 45001 strategy

The ISO 45001 Strategy needs to be written as outlined in the standard guide while considering the various hazards specific to the manufacturing industry. It should have guidelines and steps to overcome workplace health and safety risk.

Below are some examples for you to refer:

How to overcome spillage?

How to improve housekeeping?

What steps shall be taken to overcome runway blocks or falls?

How to prevent food contamination of employees?

What measures can be taken to prevent accidents when at work?

6) Implementing ISO 45001 Strategy

Now, once you have covered the entire risk landscape of your company and what can be done to overcome them, the next step is implementing them in compliance with the ISO 45001 Standard.

You can take professional help from consultants who are experts in the implementation of the ISO 45001 Standard.

Anitech will be happy to help you with any queries on implementation. You can call us on 1300 802 163 or e-mail at – info@anitechgroup.com or enquire here.

7) Training and Awareness Programs

Training and Awareness Programs
Training and Awareness Programs

Training employees is essential to help employees from getting injured. The awareness programs can provide information on the various health and safety hazards in a manufacturing unit. With the training procedures, you can guide employees and workers who do manual labour on handling equipment, housekeeping, wearing protective suits and gear, walking carefully, reporting any difficulty faced immediately, not eating near work plants, practising hygiene etc.

8) Management Support

Management Support
Management Support

All this is possible only with the support of the Company’s management. Interaction between the management and employees can further help in overcoming workplace health and safety hazards.

For more details, on the implementation of ISO 45001 Standard in your manufacturing industry, read here.

How Can Anitech Assist in ISO 45001 Implementation?

Anitech is renowned for its robust implementation of the ISO 45001 standard for various industries. We can analyse your Company’s workplace environment, conduct a gap analysis and find shortcomings. Based on the audit, our OH&S Consultants will create a robust plan to implement ISO 45001 standard at your Company.

We will also assist you in getting certified and working as your extended team.

If you are looking for an advisor to help you enhance your Company’s workplace health and safety and boost your business, do reach out to us.

Anitech is a call away from you. Do call us on 1300 802 163 or e-mail at – info@anitechgroup.com or enquire here.

Our consultants will be happy to help.


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