HAZARD IDENTIFICATION, RISK ASSESSMENT AND RISK CONTROL TABLE

CRIMPING PROCESS
HAZARD IDENTIFICATION RISK ASSESMENT
NO ACTIVITIES RISK RISK RISK CONTROL
HAZARD EFFECT CURRENT RISK CONTROL L S CATEGORY
SCORE RATING
Take Wire from cutting rack Ergonomic -Awkward posture back pain PPE: Safety Shoe 3 1 3 Low Risk HEALTH a)Elimination : -
b) Substitution :
c) Isolation : -

d)Engineering Control :1. Design new rack follow the

average operator height. Adjustable rack 2. eliminate
1 excessive force and awkward postures and allow workers to
maintain optimal joint positions
e)Adminitrative Control : 1,SOP,2:Awareness ergonomic
training, signage, 3.Buddy system. 4.Implement rests or
stretch breaks to increase recovery 5.Provide proper lifting

f)PPE : -

read kamban wire to choose terminal Ergonomic : Repeatitive task 1.Eyes stress not available 2 1 2 Low Risk HEALTH a)Elimination : -
b) Substitution :
c) Isolation : -
d)Engineering Control :1. Design new desk follow the
average operator height. Adjustable desk 2. eliminate
2 excessive force and awkward postures and allow workers to
maintain optimal joint positions
e)Adminitrative Control : 1,SOP,2:Awareness ergonomic
training, signage, 3.Buddy system. 4.Implement rests or
stretch breaks to increase recovery 5.Provide proper lifting
and other work techniques
f)PPE : -
take terminal in rack and install in Ergonomic -Awkward posture back pain PPE: Safety Shoe 2 1 2 Low Risk HEALTH a)Elimination : -
crimping machine b) Substitution :
c) Isolation : -
d)Engineering Control :1. modify machine terminal bar
follow the average operator height. Adjustable machine
terminal bar. 2. eliminate excessive force and awkward
3 postures and allow workers to maintain optimal joint
positions
e)Adminitrative Control : 1,SOP,2:Awareness ergonomic
training, signage, 3.Buddy system. 4.Implement rests or
stretch breaks to increase recovery 5.Provide proper lifting
and other work techniques
f)PPE : -
take applicator and install at machine Ergonomic : back pain PPE: Safety Shoe 3 1 3 Low Risk HEALTH a)Elimination : -
b) Substitution :
c) Isolation : -
d)Engineering Control :1. Design new rack follow the
average operator height. Adjustable rack 2. eliminate
4 excessive force and awkward postures and allow workers to
maintain optimal joint positions
e)Adminitrative Control : 1,SOP,2:Awareness ergonomic
training, signage, 3.Buddy system. 4.Implement rests or
stretch breaks to increase recovery 5.Provide proper lifting
and other work techniques
f)PPE : -
Insert terminal in applicator excess terminal chip finger injury not available 3 1 3 Low Risk SAFETY a)Elimination : -
b) Substitution
c) Isolation
1. Providing adequate staffing and adjusting work
schedules.2.Providing regular information and training.3.
5 Provide First Aid Kit during the operation.
e)Adminitrative Control :1.Conduct Safety Toolbox
Meeting each time prior to starting of the work.2. Safe work
procedure.

f)PPE: Cotton Glove

take wire sample Ergonomic : Repeatitive task stress not available 1 1 1 Low Risk HEALTH a)Elimination : -
b) Substitution :
c) Isolation : -

d)Engineering Control :1. Design new rack follow the

average operator height. Adjustable rack 2. eliminate
6 excessive force and awkward postures and allow workers to
maintain optimal joint positions
e)Adminitrative Control : 1,SOP,2:Awareness ergonomic
training, signage, 3.Buddy system. 4.Implement rests or
stretch breaks to increase recovery 5.Provide proper lifting

f)PPE : -

crimp wire sample for spec terminal 1, Applicator moving part finger injury Engineering Control : safety cover 2 1 1 Low Risk SAFETY a)Elimination : -
b) Substitution
c) Isolation
1. Providing adequate staffing and adjusting work
schedules.2.Providing regular information and training.3.
Provide First Aid Kit during the operation.
e)Adminitrative Control :1.Conduct Safety Toolbox
Meeting each time prior to starting of the work.2. Safe work
procedure.

f)PPE: Cotton Glove

2,Flying chip eyes injury PPE: Goggle 2 1 2 Medium Risk SAFETY a)Elimination : -
b) Substitution
c) Isolation : 1.Guards or restrictor plates should be fitted to
equipment where appropriate.
d)Engineering Control: 1. Modify current safety cover to
protect this hazard.
7 e)Adminitrative Control :1.safe work procedure. 2.Conduct
Safety Toolbox Meeting each time prior to starting of the
work. 3.Display Safety Signage to remind workers about the
hazards.

f)PPE: 1.Goggle
3. Applicator Sharp moving blade finger injury Engineering Control : 1.Safety cover. 2. 3 3 9 Medium Risk SAFETY a)Elimination :-
Stopper b) Substitution
c) Isolation
d)Engineering Control: 1. Modify current safety cover to
protect this hazard.2.Apply safety emergency button,

e)Adminitrative Control:1.Providing adequate staffing and

adjusting work schedules.2.Providing regular information
and training.3. Provide First Aid Kit during the operation.
4.Conduct Safety Toolbox Meeting each time prior to
starting of the work 5.Weekly maaintenance for applicator

f)PPE: 1.Gloves (cutting resistant gloves, double gloving)

pull test wire Ergonomic : Repeatitive task stress not available 1 1 1 HEALTH a)Elimination
b) Substitution
8 c) Isolation
d)Engineering Control
e)Adminitrative Control
f)PPE
Take real wire for crimping 1. Cumulative of noise from hearing lost / deficiency PPE:using ear plug 3 2 6 Medium Risk HEALTH a)Elimination :-
machine b) Substitution;1,:purchase new auto cutting machine to
eliminate all crimping machine
c) Isolation :

d)Engineering Control :1Separating the noisy area from

other workspaces by a sound-reducing partition.2.Enclosure
of noisy machinery with sound-absorbing material (effect
may be limited unless total enclosure is achieved.3.Repairing
and replacing loose rotating parts, worn bearings and gears.
4. Install noise blocking layer at the back part of crimping
machines.5. Install additional noise absorber layer of the
crimping machine motor.6.Continue with regular
maintenance of equipment, record of preventive
maintenance must be kept.

9
 e)Adminitrative Control:1. Identifying hearing protection
zones and clearly sign-posting noisy areas.2.providing rest
breaks in areas away from a noisy work
environment.3.organising schedules so that noisy tasks are
performed when as few people as possible are
present.4.limiting the time workers spend in noisy areas by
job design and job rotation at less than 2 hours 21 minutes
per shift to limit the exposure of employee below excessive
noise level. 5. Personal hearing protector must be regularly
inspected, maintained and readily made available.
6. Continue to supply personal hearing protector with NRR
of 27 dB as an interim measure until and unless effective
engineering or administrative control measure are
implemented.

f)PPE:1.PHP (Personal Hearing Protector) Ear Muff, Ear

Plug
2, Applicator moving part finger injury Engineering Control : safety cover 3 1 3 Low Risk SAFETY a)Elimination : -
9 b) Substitution
c) Isolation
1. Providing adequate staffing and adjusting work
schedules.2.Providing regular information and training.3.
Provide First Aid Kit during the operation.
e)Adminitrative Control :1.Conduct Safety Toolbox
Meeting each time prior to starting of the work.2. Safe work
procedure.

f)PPE: Cotton Glove

3. Flying chip eyes injury PPE: Goggle 3 2 6 Medium Risk SAFETY a)Elimination : -
b) Substitution
c) Isolation : 1.Guards or restrictor plates should be fitted to
equipment where appropriate.
d)Engineering Control: 1. Modify current safety cover to
protect this hazard.
e)Adminitrative Control :1.safe work procedure. 2.Conduct
Safety Toolbox Meeting each time prior to starting of the
work. 3.Display Safety Signage to remind workers about the
hazards.

f)PPE: 1.Goggle
4. Applicator Sharp moving blade finger injury Engineering Control : 1.Safety cover. 2. 3 3 9 Medium Risk SAFETY a)Elimination :-
Stopper b) Substitution
c) Isolation
d)Engineering Control: 1. Modify current safety cover to
protect this hazard.2.Apply safety emergency button,

e)Adminitrative Control:1.Providing adequate staffing and

adjusting work schedules.2.Providing regular information
and training.3. Provide First Aid Kit during the operation.
4.Conduct Safety Toolbox Meeting each time prior to
starting of the work 5.Weekly maaintenance for applicator

f)PPE: 1.Gloves (cutting resistant gloves, double gloving)

10 Quality wire random check sharp strip wire finger injury not available 3 1 3 Low Risk SAFETY a)Elimination : -
b) Substitution
c) Isolation
d)Engineering Control :
e)Adminitrative Control : 1. Providing regular information
and training. 2.Safe work procedure. 3.Conduct Safety
Toolbox Meeting each time prior to starting of the
work.4.Provide First Aid Kit and Fire Extinguisher
duringthe operation

f)PPE 1.Cotton Gloves

11 Install cup for wire for crimping and Ergonomic : Repeatitive task stress not available 1 1 1 HEALTH a)Elimination : -
terminal b) Substitution :
c) Isolation : -
d)Engineering Control :1. Design new rack follow the
average operator height. Adjustable rack 2. eliminate
excessive force and awkward postures and allow workers to
maintain optimal joint positions
e)Adminitrative Control : 1,SOP,2:Awareness ergonomic
training, signage, 3.Buddy system. 4.Implement rests or
stretch breaks to increase recovery 5.Provide proper lifting
and other work techniques
f)PPE : -
12 Finished Wire put on the rack junkan Ergonomic : Repeatitive task back pain not available 2 1 2 HEALTH a)Elimination : -
b) Substitution :
c) Isolation : -
d)Engineering Control :1. Design new rack follow the
average operator height. Adjustable rack 2. eliminate
excessive force and awkward postures and allow workers to
maintain optimal joint positions
e)Adminitrative Control : 1,SOP,2:Awareness ergonomic
training, signage, 3.Buddy system. 4.Implement rests or
stretch breaks to increase recovery 5.Provide proper lifting
and other work techniques
f)PPE : -