This document outlines standard risk assessment procedures for product design and manufacture, relevant to Cambridge A-Level Design and Technology (9705).
What is a Risk Assessment?
A risk assessment is a systematic process of identifying hazards, evaluating the risks associated with those hazards, and implementing control measures to reduce the risks to an acceptable level. It's a crucial part of ensuring a safe working environment.
The Risk Assessment Process
Identify the Hazards: What could cause harm?
Identify Who Might Be Harmed: Who could be affected by the hazard?
Evaluate the Risks: How likely is harm to occur, and how serious would that harm be?
Control the Risks: What can be done to prevent or reduce the risk?
Review and Update: Regularly check the risk assessment and update it as needed.
Step 1: Identifying Hazards
Hazards are anything that could cause harm. Examples in product design and manufacture include:
Sharp objects (knives, lasers)
Moving machinery (lathes, mills)
Electrical hazards (power tools, wiring)
Chemicals (solvents, adhesives)
Noise
Dust
Manual handling (lifting, carrying)
Ergonomics (awkward postures)
Fire
Step 2: Identifying Who Might Be Harmed
Consider everyone who could be affected by the hazard. This might include:
The designer
The manufacturer
Other workers in the area
Maintenance staff
Customers (if applicable)
Step 3: Evaluating the Risks
Risk is the likelihood of harm occurring and the severity of that harm. A common way to evaluate risk is using a risk matrix:
Likelihood
Severity
Risk Level
Very Likely
Serious
Extreme
Likely
Serious
High
Likely
Moderate
Medium
Possible
Serious
Medium
Likely
Minor
Low
Possible
Minor
Low
Unlikely
Minor
Low
Risk Levels:
Extreme: Immediate action required. Work should not proceed until the risk is controlled.
High: Action required as soon as possible. Control measures should be implemented quickly.
Medium: Action should be taken within a reasonable timeframe.
Low: Monitor the risk and review the assessment periodically.
Step 4: Controlling the Risks
Control measures should be implemented in the following order of priority (the hierarchy of controls):
Elimination: Remove the hazard altogether. (e.g., use a different material)
Substitution: Replace the hazard with a less hazardous alternative. (e.g., use a water-based paint instead of a solvent-based paint)
Engineering Controls: Implement physical changes to the workplace to reduce the risk. (e.g., install machine guards, ventilation systems)
Administrative Controls: Change the way work is done to reduce the risk. (e.g., implement safe work procedures, provide training)
Personal Protective Equipment (PPE): Provide workers with equipment to protect them from the hazard. (e.g., safety glasses, gloves, hearing protection) - This is the last line of defence.
Step 5: Review and Update
Risk assessments should be reviewed regularly, especially when:
There are changes to the design or manufacturing process.
New hazards are identified.
An incident or near miss occurs.
Control measures are not effective.
Example Risk Assessment - Using a Lathe
Suggested diagram: A person operating a lathe with appropriate PPE (safety glasses, hearing protection).
Hazard
Who Might Be Harmed
Risk
Control Measures
Rotating workpiece
Operator, nearby workers
High
Machine guards, operator training, use of appropriate PPE (safety glasses)