Risk Register Risk Register 7
" "" #
Risk Area/Process
Activity
Identifed Risk Scenario
Assessment9 deployment9 O8ce o the eneral implementation9 revie39 ail%re to cond%ct e;ective strategic )anager and ad:%stment phase o $%siness plan S+PP
<)-RS=""0 Rev> ""
Severity
Overall Risk !ikelihood
Risk !e !evel
$%siness loss
&
C
'I'
.CAO)""#
.sta$lish proced%re or reg%lar cond%ct o revie3s and deployment meetings
O)
Impact
Reerence
Prevention/)itigation Action(s
Person-in-charge
Revie3 o $%siness perormance
,navaila$le data
-delay in $%siness perormance revie3 -delay in setting goals and targets
C
).I,)
.CAO)""*
-do%$le time in preparing the $%dget -resched%ling o the activity
O)
+%dgeting
Setting goals and targets
Setting o %nrealistic goals and targets
misappropriation o reso%rces
&
'I'
.CAO)""
revie3 action plans and variances
O)
" "" 0
+%dgeting
issemination o goals and target
misinterpretation o goals and targets
misappropriation o reso%rces
&
'I'
.CAO)""
revie3 action plans and variances
O)
" "" &
+%dgeting
miscalc%lation
misappropriation o reso%rces
&
'I'
.CAO)""
revie3 action plans and variances
O)
" "" 1
+%dgeting
Revie3 o action plans and misinterpretation/miscalc%lation $%dget
misappropriation o reso%rces
&
'I'
.CAO)""
revie3 action plans and variances
O)
" "" 2
+%dgeting
Revie3 o action plans and delay in revie3ing $%dget drats $%dget
misappropriation o reso%rces
&
'I'
.CAO)""
revie3 action plans and variances
O)
revie3 action plans and variances
O) O)
" "" *
+%dgeting
" ""
" "" 4
+%dgeting
Revision o $%dget drats
miscalc%lation
misappropriation o reso%rces
&
'I'
.CAO)""
" "" 5
+%dgeting
Revie3 o $%dget drats and preparation o master miscalc%lation $%dget
misappropriation o reso%rces
&
'I'
.CAO)""
revie3 action plans and variances
" "# "
+%dgeting
Presentation to President or approval
delay in perorming pro:ected activity
&
'I'
.CAO)""
revie3 action plans and variances
O)
" "# #
+%dgeting
Revision o master $%dget discrepancy in $%dget fg%res drat
misappropriation o reso%rces
&
'I'
.CAO)""
revie3 action plans and variances
O)
" "# *
+%dgeting
)onitoring perormance
inacc%rate data
$%siness loss
&
'I'
.CAO)""
revie3 action plans and variances
O)
" "#
+%dgeting
Cond%cting corrective/preventive action
inappropriate analysis
rec%rrence rec%rrence o pro$lem/$%siness loss
&
'I'
.CAO)""
revie3 action plans and variances
O)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
disapproval
" "# 0
Identifcation o 'a6ard/Aspect occ%pational health and Identifcation and Risk saety Assessment ha6ards/environmental aspects per activity
ail%re to indentiy certain ha6ard/impact
occ%rrence o incident
&
+
).I,)
" "# &
Identifcation o 'a6ard/Aspect occ%pational health and Identifcation and Risk saety Assessment ha6ards/environmental aspects per activity
section/department representative not availa$le
delay in cond%cting the assessment
+
).I,)
Choose gro%p o skilled/trained assessor in .CA-.'S""0 cond%cting assessment or $rainstorming
I)R
Contingency Action(s
So%rce or $ack-%p reso%rce persons to cond%ct analysis
Person-in-charge
I)R
""#1
'a6ard/Aspect Identifcation o associated Identifcation and Risk ha6ards or health9 saety ail%re to identiy a certain ha6ard/impact Assessment and e nvironmental nvironmental
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""#2
'a6ard/Aspect Identifcation and Risk
delay in implementation o needed program
+
).I,)
.CA-.'S""&
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""#4
'a6ard/Aspect
delay in implementation o needed program
+
).I,)
.CA-.'S""&
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""#5
'a6ard/Aspect Implementation o Identifcation and Risk approved programs/action ail%re to implement the programs Assessment plans
occ%rrence o incident
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""*"
'a6ard/Aspect Revie3 o risk assessment ail%re to make controls analysis Identifcation and Risk and controls Assessment
delay in implementation o needed program
+
).I,)
.C .CA-.'S""&
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
).I,)
-Reg%lar %pdating o company and other re?%irement register thr% 3e$sites/visit to government li$raries .CA-.'S""* -Incl%de BIS re?%irements re?%irements in the 3ork instr%ctions posted in the 3ork area> -.sta$lish proced%re or handling c%stomer complaints>
I)R
).I,)
-Reg%lar %pdating o company and other re?%irement register thr% 3e$sites/visit to government li$raries .CA-.'S""* -Incl%de BIS re?%irements re?%irements in the 3ork instr%ctions posted in the 3ork area> -.sta$lish proced%re or handling c%stomer complaints>
I)R
).I,)
-ro%p o skilled/trained assessor is %sed in cond%cting the assessment or .CA-.'S""0 $rainstorming -competence o SO/PCO on %pdating the register -Competence o SO/PCO in eval%ating reports
I)R
""*#
Identifcation and Compliance to Applica$le !egal other re?%irements re?%irements
""**
Identifcation and Compliance to Applica$le !egal other re?%irements re?%irements
""*
Identifcation and Compliance to Applica$le !egal other re?%irements re?%irements
ail%re to make controls analysis
Receipt and revie3 o ne3 la3s9 reg%lations9 and reg%latory inractions/c%stomer ail%re to have the %pdate o re?%irements> code o practice9 and other complaints re?%irements
@erifcation o applica$ility
rong :%dgment i the re?%irement is applica$le or not>
,pdate o legal and other ,navaila$ility o SO/PCO re?%irement register
reg%latory inractions/c%stomer complaints
delay in %pdating the register>
0
0
+
+
+
So%rce or $ack-%p reso%rce reso%rce persons to cond%ct analysis
""*0
Internal/.Dternal Comm%nication
""*&
Internal/.Dternal Comm%nication
""*1
Internal/.Dternal Comm%nication
Comm%nication roll o%t
ail to comm%nicate inormation
Processing o CAEs and PAEs and then cond%cting ail%re to prepare the necessary CA/PA risk Assessment
Circ%lation o resol%tions (CAEs and PAEs
ail%re to circ%late the resol%tions
violation to any re?%irements
0
+
).I,)
-Reg%lar %pdating o company and other re?%irement register thr% 3e$sites/visit to government li$raries .CA-.'S""* -Incl%de BIS re?%irements re?%irements in the 3ork instr%ctions posted in the 3ork area> -.sta$lish proced%re or handling c%stomer complaints>
I)R
I)R
rec%rrence rec%rrence o pro$lem or inractions to re?%irements re?%irements
0
+
).I,)
-Reg%lar %pdating o company and other re?%irement register thr% 3e$sites/visit to government li$raries .CA-.'S""* -Incl%de BIS re?%irements re?%irements in the 3ork instr%ctions posted in the 3ork area> -.sta$lish proced%re or handling c%stomer complaints>
pending o the matter that needs clos%re
0
+
).I,)
.CA-.'S""
I)R
-)aDimi6e processing time or handling c%stomer -coordinate 3ith the re?%esting party or the reasons o delay
I)R
rec%rrence rec%rrence o pro$lem or inractions to re?%irements re?%irements
0
+
).I,)
-Reg%lar %pdating o company and other re?%irement register thr% 3e$sites/visit to government li$raries .CA-.'S""* -Incl%de BIS re?%irements re?%irements in the 3ork instr%ctions posted in the 3ork area> -.sta$lish proced%re or handling c%stomer complaints>
.mergency Preparedness and Control
Revie3 o risk assessment needed actions may not $e ail%re to revie3 the risk assessment res%lts res%lt implemented
+
).I,)
.CA-.'S""&
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""*5
.mergency Preparedness and Control
Identifcation o ail%re to identiy some ha6ards/aspects o ha6ards/aspect ha6ards/aspect that 3o%ld the activity lead to an emergency>
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
"""
.mergency Preparedness and Control
evelopment/revie3 o emergency p roced%res roced%res
ail%re to develop emergency proced%res
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""#
.mergency Preparedness and Control
Implementation o proced%re/cond%cting trainings
ail%re to implement the esta$lished proced%res
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""*
Operational control
Revie3 o the risk assessment res%lt
ail%re to revie3 the risk assessment res%lts oc occ%rrence o incident
&
+
).I,)
.CA-.'S""#
oose oose gro%p gro%p o skilled/trained assessor in cond%cting assessment or $rainstormin
I)R
""*2
Internal/.Dternal Comm%nication
""*4
Implementation o CAEs and PAEs
ail%re to incl%de the necessary CA/PA
""
Operational control
Identifcation o medi%m and high risk aspects/ha6ards that 3o%ld re?%ire p roced%ral control
ail%re to identiy some ha6ards/aspects o the activity
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""0
Operational control
evelopment o proced%res then (0cond%cting risk assessment
ail%re to consider the identifed ha6ard/aspects
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""&
Operational control
Implementation o proced%re
ail%re to implement the esta$lished proced%res
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""1
Operational control
ail%re to give the training needed
occ%rrence o incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
""2
Operational control
necessary corrective action 3ill not $e implemented
C
).I,)
.CA-.'S""&
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
necessary emergency responses may not $e done
).I,)
.CA-.'S""1
.sta$lished company r%les and reg%lations o incident/accident reporting
I)R
I)R
""4
Graining o concerned personnel
)onitoring or compliance ail%re to monitor proced%re e;ectiveness e;ectiveness
Inorming ail%re to inorm the concerned Incident Investigation s%pervisor/company n%rse s%pervisor/company n%rse o any incident that occ%rs
3orsening o the victimEs sit%ation
&
+
).I,)
-Choose gro%p o skilled/trained assessor in cond%cting assessment .CAor $rainstorming .'S""#9 -Availa$ility o company .CA-.'S""2 clinic9 n%rse and trained frst aiders -.mployees are provided 3ith health card
.val%ation o accident report then revie3 o ail%re to eval%ate accident report eDisting 'AIRA9 .PC9 .RI
rec%rrence o the incident
&
+
).I,)
.CA-.'S""#
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
Implementation and monitoring approved recommendation and cond%cting verifcation
ail%re to monitor corrective/preventive actions
necessary corrective actions may not $e implemented and e;ective
+
).I,)
.CA-.'S""&
Choose gro%p o skilled/trained assessor in cond%cting assessment or $rainstorming
I)R
Installation o ne3 He3 Inrastr%ct%re/ e?%ipment and/or .?%ipment Installation inrastr%ct%re
!ack o saeg%ards installed over moving parts o machines installed
ma:or in:%ry
+
).I,)
-Availa$ility o company clinic9 n%rse and trained .CA-.'S""2 frst aiders -.mployees are provided 3ith health card
PCO/SO/ I)R
""0
Records management
ail%re to keep important record
no evidence to present d%ring a%dits
0
C
).I,)
.sta$lished proced%re or .CA-FA""# corrective/preventive action
I)R/CC
""00
Records management
0
C
).I,)
.CA-FA""#
""5
Incident Investigation
Sending victim to treatment
""0"
Incident Investigation
""0#
Incident Investigation
""0*
)onitoring o active and archive fles
delayed treatment
Availa$ility o fre eDting%isher in the area
I)R/CC
""0&
'andling C%stomer Complaints
Receipt and eval%ation o !ack o inormation a$o%t the complaint complaint
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on . CA-FA""* corrective/preventive action
I)R
""01
'andling C%stomer Complaints
Cond%cting corrective/preventive action
Ins%8cient root ca%se analysis
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""02
'andling C%stomer Complaints
Inorming the c%stomer
ail%re to inorm c%stomer a$o%t the corrective/preventive action
delay closing o complaint
C
).I,)
.CA-FA""
.sta$lished proced%re or di;erent FA activities
I)R
""04
Internal I)S A%dit
Act%al a%dit
ail%re to identiy strengths and areas or improvement
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""05
Internal I)S A%dit
Act%al a%dit
.Dpos%re to ha6ards on di;erent area sched%led or a%dit
in:%ry
C
).I,)
.CA-FA""0
-.sta$lishment o
I)R
""&"
Process )onitoring and )eas%rement
no evidence to present d%ring a%dits
0
C
).I,)
.CA-FA""#
Availa$ility o fre eDting%isher in the area
I)R
""
Process )onitoring and )eas%rement
S%$mission o report to I)R
late s%$mission o report
delayed cond%ct o revie3s
C
).I,)
.CA-FA""
.sta$lished proced%re or di;erent FA activities
I)R
""&*
Analysis o ata
Receipt o reports rom vario%s sections/departments
ail to collect reports
delayed analysis
C
).I,)
.CA-FA""
.sta$lished proced%re or di;erent FA activities
I)R
""&
Analysis o ata
!ate s%$mission o statistical report
delayed implementation o action plan
C
).I,)
.CA-FA""
.sta$lished proced%re or di;erent FA activities
I)R
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
Preparation o reports s%pporting perormance !acking details on s%pport doc%ments indicators
""&0
Identifcation o Corrective/ Preventive potential/eDisting Action nonconormity
""&&
@erifcation and analysis o Corrective/ Preventive poor verifcation analysis o potential/eDisting Action nonconormity nonconormity
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""&1
etermining the ca%se o Corrective/ Preventive potential/eDisting Action nonconormity
poor root ca%se analysis
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""&2
Sol%tion orm%lation and Corrective/ Preventive %pdate/cond%ct o risk Action assessment
orm%lation o ine;ective action plans
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""&4
Corrective/ Preventive Implementation o Action approved action plans
!ate implementation o action plans
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""&5
Revie3 and recording o Corrective/ Preventive actions taken and Action standardi6ation o implemented action
ail%re to revie3 the e;ectiveness o action occ%rrence/rec%rrence o plans potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""1"
Corrective/ Preventive Closing o%t o the Action nonconormity
occ%rrence/rec%rrence o potential/eDisting pro$lems
0
C
).I,)
.sta$lished proced%re on .CA-FA""* corrective/preventive action
I)R
""1#
Sot3are and +acking %p all data (fles 'ard3are )aintenance and programs
loss o records and program
C
).I,)
.CA-FA""&
Retrieve data9 program or $ack%p
IG Personnel
""1*
Sot3are and +acking %p all data (fles 'ard3are )aintenance and programs
.Dternal hard drive is not in good 3orking condition
loss o records and program
C
).I,)
.CA-FA""&
Retrieve data9 program or $ack%p
IG Personnel
""1
Sot3are and F%arantine o inected 'ard3are )aintenance fles
loss o data and program
C
).I,)
.CA-FA""&
Retrieve data9 program or $ack%p
IG Personnel
""10
Sot3are and Cleaning/healing o 'ard3are )aintenance inected fles
loss o data and program
C
).I,)
.CA-FA""&
Retrieve data9 program or $ack%p
IG Personnel
""1&
Sot3are and Copying clean fle(s to 'ard3are )aintenance recent $ack%p
loss o data and program
C
).I,)
.CA-FA""&
Retrieve data9 program or $ack%p
IG Personnel
""11
Sot3are and Copying clean fle(s to 'ard3are )aintenance recent $ack%p
loss o %pdate data to $ack%p drive
C
).I,)
.CA-FA""&
Retrieve data9 program or $ack%p
IG Personnel
""12
Sot3are and Cond%cting preventive 'ard3are )aintenance maintenance
eDpos%re to radiation
ill health
A
).I,)
.CA-FA""1
""14
C%stomer Satisaction Cond%cting c%stomer etermination s%rvey
.Dpos%re to comp%ter radiation
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
""15
C%stomer Satisaction ather the iss%ed etermination c%stomer s%rvey
Incomplete n%m$er o s%rvey res%lts
incomplete analysis report or n%m$er o c%stomers
*
C
).I,)
.CA-SA)""4
Revise proced%re to acco%nt or monitoring ollo3-%p and timeliness o sending o the s%rvey>
Acco%nt .Dec%tive9 Sales and )arketing )anager
""2"
C%stomer Satisaction ather the iss%ed etermination c%stomer s%rvey
.Dpos%re to comp%ter radiation
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
IG Personnel
""2#
In?%iry and Order 'andling
Preparation and s%$mission o ?%otation and dra3ing
Inacc%rate prod%ct specifcation dra3ing 3rong order/prod%ct vs> c%stomer re?%irement specifcations
C
).I,)
.CA-SA)""2
Acco%nt .Dec%tive9 Sales and )arketing )anager
""2*
In?%iry and Order 'andling
Preparation and s%$mission o ?%otation and dra3ing
.Dpos%re to comp%ter radiation
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
""2
In?%iry and Order 'andling (!ocal
Preparation and signing o .Dpos%re to comp%ter radiation :o$ order
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
).I,)
-Ghoro%gh coordination 3ith the c%stomers or the iss%ance o :o$ orders Acco%nt or p%rchase orders on .Dec%tive9 Sales .CA-SA)""# time> and )arketing .sta$lished proced%re or )anager handling c%stomer complaints
).I,)
-Ghoro%gh coordination 3ith the c%stomers or the iss%ance o :o$ orders Acco%nt or p%rchase orders on .Dec%tive9 Sales .CA-SA)""# time> and )arketing .sta$lished proced%re or )anager handling c%stomer complaints
).I,)
-Ghoro%gh coordination 3ith the c%stomers or the iss%ance o :o$ orders Acco%nt or p%rchase orders on .Dec%tive9 Sales .CA-SA)""# time> and )arketing .sta$lished proced%re or )anager handling c%stomer complaints
""20
""2&
""21
Order 'andling (.Dport
Order 'andling (.Dport
Order 'andling (.Dport
Receipt o Bo$ Order
Receipt o Bo$ Order
Receipt o Bo$ Order
,na$le to receive :o$ order
!oss o Bo$ Order
!ate receipt o :o$ orders
elay o delivery to the c%stomer
C%stomer complaint
elay and prod%ction delivery
0
0
0
+
+
+
.Dpos%re to d%st
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
.ncoding to Bo$ Order then printing and signing Bo$ Order
rong encoding o :o$ orders
elayed delivery
C
).I,)
-o%$le checking o <@C .CA-SA)""* Bo$ Order vs> <=C Bo$ Order
Acco%nt .Dec%tive9 Sales and )arketing )anager
.ncoding to Bo$ Order then printing and signing Bo$ Order
.Dpos%re to comp%ter radiation
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
Prospecting
Creating list o prospective .Dpos%re to comp%ter radiation c%stomer
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
""4#
Prospecting
Identifcation and ?%alifcation o potential c%stomer
.Dpos%re to comp%ter radiation
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
""4*
Prospecting
Presentation and demonstration
.Dpos%re to d%st9 heat and others>
illness/discomort
0
C
).I,)
.CA-SA)""0
Ann%al physical eDamination
Acco%nt .Dec%tive9 Sales and )arketing )anager
""4
Prospecting
'andling o$:ections and closing
Incapa$ility o closing the deal
Ho ne3 c%stomer
*
C
).I,)
-Cover n action plans or SOG Analysis or SA) .CA-SA)""5 -Additional headco%nt )anager and .ngineer -API9 ,!9 <) certifcation
Acco%nt .Dec%tive9 Sales and )arketing )anager
""40
elivery(!ocal .Dport
Receipt o delivery sched%le rom Prod%ction )anager
,na$le to sched%le the delivery
elay o delivery to the c%stomer
0
+
).I,)
.CA-SA)""&
-Constant monitoring o re?%ired delivery date o c%stomers -.sta$lished proced%re or handling c%stomer complaints
Acco%nt .Dec%tive9 Sales and )arketing )anager
""4&
elivery(!ocal .Dport
Receipt o delivery sched%le rom Prod%ction )anager
!ate receipt o advice
elay o delivery to the c%stomer
0
+
).I,)
-Constant monitoring o re?%ired delivery date o c%stomers .CA-SA)""& -.sta$lished proced%re or handling c%stomer complaints
Acco%nt .Dec%tive9 Sales and )arketing )anager
""41
elivery(!ocal .Dport
Sched%ling and determination o delivery destination
,na$le to sched%le the delivery
elay o delivery to the c%stomer
0
+
).I,)
-Constant monitoring o .CA-SA)""& re?%ired delivery date o c%stomers
Acco%nt .Dec%tive9 Sales and )arketing )anager
""42
elivery(!ocal .Dport
Sched%ling and determination o delivery destination
,na$le to sched%le the delivery
C%stomer complaint
0
+
).I,)
-.sta$lished proced%re .CA-SA)""& or handling c%stomer complaints
Acco%nt .Dec%tive9 Sales and )arketing )anager
""44
elivery(!ocal .Dport
Preparation and signing sales doc%ments
.Dpos%re to comp%ter radiation
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
""22
Order 'andling (.Dport
""24
Order 'andling (.Dport
""25
Order 'andling (.Dport
""4"
Checking o stock availa$ility rom FC 3areho%se>
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
""45
elivery(!ocal .Dport
.ndorse container/ha%ler to Prod%ction )anager or Over3eight load loading
Penalty to the shipping line
0
C
).I,)
-Confrmation rom Prod%ction )anager o act%al 3eight o the items or delivery -o%$le checking o .CA-SA)""1 doc%ments needed or delivery -.sta$lished proced%re or handling c%stomer complaints
Acco%nt .Dec%tive9 Sales and )arketing )anager
Acco%nt .Dec%tive9 Sales and )arketing )anager
""5"
elivery(!ocal .Dport
.ndorse container/ha%ler to Prod%ction )anager or Over3eight load loading
delay delivery to the c%stomer
0
C
).I,)
-Confrmation rom Prod%ction )anager o act%al 3eight o the items or delivery -o%$le checking o .CA-SA)""1 doc%ments needed or delivery -.sta$lished proced%re or handling c%stomer complaints
""5#
elivery(!ocal .Dport
elivery
Reckless driving
)a:or in:%ry
&
+
).I,)
.CA-S""5
""5*
elivery(!ocal .Dport
.Dpos%re to comp%ter radiation
.Dpos%re to comp%ter radiation
.ye irritation/discomort
0
C
).I,)
.CA-SA)""
""5
Collection
Preparation and monitoring o aging C%stomer transerred to another place sched%le o AR trade then 3aiting or d%e date
receiva$les may not $e collected
&
+
).I,)
.CA-SA)"#"
Acco%nt .Dec%tive9 Sales and )arketing )anager
""50
Collection
Preparation and monitoring o aging C%stomer ail%re to pay on d%e date sched%le o AR trade then 3aiting or d%e date
$%siness loss
&
+
).I,)
.CA-SA)"#"
Acco%nt .Dec%tive9 Sales and )arketing )anager
""5&
Collection
delay in collection
&
+
).I,)
)eeting 3ith c%stomers .CA-SA)"## or sched%led payment date and settlement
Sales and )arketing )anager
""51
Collection
delay in collection/possi$le $%siness loss
&
+
).I,)
)eeting 3ith c%stomers .CA-SA)"## or sched%led payment date and settlement
Sales and )arketing )anager
""52
Collection
Sending delin?%ency report (preparation o legal action
!egal eDpenses
$%siness loss
&
+
).I,)
)eeting 3ith c%stomers .CA-SA)"## or sched%led payment date and settlement
Sales and )arketing )anager
""54
C%stomer Accreditation
Receipt o accomplished C%stomer Inormation Sheet
$%siness loss
?
+
).I,)
.CA-SA)"#*
-Inorm c%stomer -Constant ollo3-%ps
Sales and )arketing )anager
""55
C%stomer Accreditation
,pdate o c%stomer data$ase
He3 c%stomer is added to the eDisting data$ase
Incomplete analysis report o potential c%stomer
&
+
).I,)
.CA-SA)"#
-Inorm c%stomer constant ollo3-%ps
Sales and )arketing )anager
).I,)
-Implementation o &S and records management -.sta$lished standard proced%re or control o doc%ments -Signing o process o3ners 3ho received the doc%ments .CA-PR""# -ollo3 %p thro%gh email older per palletainer $in control -monthly inventory $ased on stock card record -.sta$lish proced%re or handling c%stomer complaint
"#""
Prod%ction Planning
Revie3 o BO and dra3ing Overlook o :o$ orders and specifcations rom Sales epartment
!oss o c%stomers
&
+
Ann%al eye eDamination9 %se o eyeglasses
Acco%nt .Dec%tive9 Sales and )arketing )anager
Prod%ction )anager
-Coordinate 3ith <=C thro%gh ) in relation to the early s%$mission o BO+ Orders together 3ith the dra3ings -)onthly physical inventory to $e done to address inventory inacc%racy -additional manpo3er to s%pport physical inventory and other FC activities
Prod%ction )anager
"#"#
Prod%ction Planning
Revie3 o BO and dra3ing !ate iss%ance o BO rom Sales epartment
Revie3 o BO and dra3ing delay in delivery/c%stomer Ho dra3ing received rom Sales epartment rom Sales epartment complaint
"#"*
Prod%ction Planning
"#"
Revie3 o inventory o Prod%ction Planning items rom Bapan(<%r%ka3a =ogyo
"#"0
Prod%ction Planning
"#"&
"#"1
Prod%ction Planning
Prod%ction Planning
delay in delivery/c%stomer complaint
Revie3 o inventory o items rom Bapan(<%r%ka3a =ogyo
Revie3 o inventory o items in the plant
Revie3 o inventory o items in the plant
C
).I,)
-Implementation o &S and records management -.sta$lished standard proced%re or control o doc%ments -Signing o process o3ners 3ho received the doc%ments .CA-PR""# -ollo3 %p thro%gh email older per palletainer $in control -monthly inventory $ased on stock card record -.sta$lish proced%re or handling c%stomer complaint
).I,)
-Implementation o &S and records management -.sta$lished standard proced%re or control o doc%ments -Signing o process o3ners 3ho received the doc%ments .CA-PR""# -ollo3 %p thro%gh email older per palletainer $in control -monthly inventory $ased on stock card record -.sta$lish proced%re or handling c%stomer complaint
Prod%ction )anager
Prod%ction )anager
-.sta$lish proced%re or handling c%stomer complaint -Comply 3ith s%mmary o Bo$ Orders (internal control
Prod%ction )anager
Prod%ction )anager
-Coordinate 3ith <=C thro%gh ) in relation to the early s%$mission o BO+ Orders together 3ith the dra3ings -)onthly physical inventory to $e done to address inventory inacc%racy -additional manpo3er to s%pport physical inventory and other FC activities
Prod%ction )anager
-Coordinate 3ith <=C thro%gh ) in relation to the early s%$mission o BO+ Orders together 3ith the dra3ings -)onthly physical inventory to $e done to address inventory inacc%racy -additional manpo3er to s%pport physical inventory and other FC activities
Prod%ction )anager
Overlook <%r%ka3a =ogyoEs inventory
!oss o c%stomers
&
+
).I,)
-.sta$lish proced%re or handling c%stomer complaint .CA-PR""* -Comply 3ith s%mmary o Bo$ Orders (internal control
Copy o <=CEs inventory is not %pdated
inacc%rate orecasting o items needed
).I,)
.CA-PR""*
).I,)
-&S9 esta$lished proced%re or control o doc%ments -esta$lished proced%re or prod%ction planning .CA-PR"" -checking o inventory items -.sta$lished proced%res or handling o c%stomer complaints
Prod%ction )anager
-)onthly physical inventory to $e done to address inventory inacc%racy -additional manpo3er to s%pport physical inventory and other FC activities
Prod%ction )anager
).I,)
-&S9 esta$lished proced%re or control o doc%ments -esta$lished proced%re or prod%ction planning .CA-PR"" -checking o inventory items -.sta$lished proced%res or handling o c%stomer complaints
Prod%ction )anager
-)onthly physical inventory to $e done to address inventory inacc%racy -additional manpo3er to s%pport physical inventory and other FC activities
Prod%ction )anager
overlook on plantEs inventory
Inacc%rate inventory o valve parts
delayed delivery
delayed delivery
0
C
A
"#"2
"#"4
"#"5
"##"
"###
Prod%ction Planning
Prod%ction Planning
Prod%ction Planning
Prod%ction Planning
Prod%ction Planning
Ordering rom s%$contractor
Ordering rom s%$contractor
3rong specifcation o BO iss%ed
late delivery
Preparation o prod%ction re?%irement or the month improper 3orkload allocation (< )C'
Preparation o prod%ction re?%irement or the month improper 3orkload allocation (< )C'
istri$%ting sched%le to Prod%ction epartment 'ead
delay in distri$%tion o prod%ction re?%irements
re:ection o items
C%stomer complaint
high cost o inventory
%na$le to meet target
delay in delivery
&
+
+
+
+
+
).I,)
-Implementation o &S and records management -.sta$lished standard proced%re or control o doc%ments -Signing o process o3ners 3ho received the doc%ments .CA-PR""# -ollo3 %p thro%gh email older per palletainer $in control -monthly inventory $ased on stock card record -.sta$lish proced%re or handling c%stomer complaint
Prod%ction )anager
).I,)
-Implementation o &S and records management -.sta$lished standard proced%re or control o doc%ments -Signing o process o3ners 3ho received the doc%ments .CA-PR""# -ollo3 %p thro%gh email older per palletainer $in control -monthly inventory $ased on stock card record -.sta$lish proced%re or handling c%stomer complaint
Prod%ction )anager
).I,)
-revie3 distri$%tion o 3orkload -revie3 o accomplished tracea$ility slip -reg%lar meeting 3ith .CA-PR""0 prod%ction personnel or 3eekly sched%le -Proper revie3 o BO -.sta$lished proced%re on prod%ction planning
Prod%ction )anager
).I,)
-revie3 distri$%tion o 3orkload -revie3 o accomplished tracea$ility slip -reg%lar meeting 3ith .CA-PR""0 prod%ction personnel or 3eekly sched%le -Proper revie3 o BO -.sta$lished proced%re on prod%ction planning
Prod%ction )anager
).I,)
-doc%mented proced%re in prod%ction planningimmediate endorsement .CA-PR""4 o :o$ order rom sales -esta$lished proced%re or handling o c%stomer complaints
Prod%ction )anager
"##*
"##
"##0
Prod%ction Planning
Prod%ct stat%s
Identifcation and Gracea$ility
Preparation o prod%ction sched%le or shipping
delay in prod%ction processes
re:ection o items
&
+
).I,)
-Revie3 o BO -Inventory o casting -reg%lar meeting 3ith prod%ction personnel or .CA-PR""& 3eekly sched%le o items -.sta$lished proced%re or handling or c%stomer complaints
Receipt and encoding daily prod%ction report
eDpos%re to comp%ter radiation
.ye irritation/discomort
c
).I,)
-,se di;erent type o comp%ter monitor .CA-PR""1 -eye eDamination d%ring AP. -%se o eyeglasses
Prod%ction )anager
).I,)
-Iss%e BO and dra3ing to H -Confrm markings and specifcations vs> BO and ra3ing -Reg%lar prod%ction .CA-PR""2 meeting -.sta$lished proced%re and 3ork instr%ction or pattern preparation and checking -.sta$lished proced%re or c%stomer complaints
Prod%ction )anager
H 'ead9 Pattern S%pervisor
Attaching markings on pattern (pattern preparation
rong markings %sed
re:ection o item
0
C
Prod%ction )anager
"##&
Revie3 o dra3ing and Pattern and Core$oD checking o pattern and Preparation core$oD
delayed iss%ance o pattern
target o%tp%t not met
C
).I,)
-availa$le dra3ings readily 3ithdra3n rom H .CA-<"*0 -Iss%ance o corrective and preventive action to concerned section
"##1
Revie3 o dra3ing and Pattern and Core$oD checking o pattern and Preparation core$oD
,rgent items not listed
elayed delivery
C
).I,)
.CA-<"*0
-availa$le dra3ings readily 3ithdra3n rom H -Iss%ance o corrective and preventive action to concerned section
H 'ead9 Pattern S%pervisor
).I,)
-Check sheet history or provided to $e flled %p 3henever the pattern %ndergoes repair -BO 3ith specifed changes on dimensions .CA-<"*0 and markings are given to pattern s%pervisor -remelting o re:ected items -iss%ance o corrective and preventive action to concerned section
H 'ead9 Pattern S%pervisor
).I,)
-Preventive maintenance is cond%cted $y maintenance department -Saety $elt and ladder is .CA-<"*# %sed -availa$ility o company clinic9 n%rse and trained frst aiders
Pattern S%pervisor
"##2
"##4
Revie3 o dra3ing and Pattern and Core$oD checking o pattern and Preparation core$oD
Pattern and Core$oD Retrieval o dra3ing9 Preparation pattern and core$oD
Pattern records not %pdated
orkers might $e hit $y alling items
internal re:ection
in:%ry/atality
*
&
+
"##5
Pattern and Core$oD Retrieval o dra3ing9 Preparation pattern and core$oD
"#*"
Pattern and Core$oD Pattern repair Preparation
"#*#
Pattern and Core$oD Pattern repair Preparation
"#**
Pattern and Core$oD Pattern repair Preparation
,sing and handling c%tting tools(rip sa39 $and sa39 etc>
eneration o 3aste (c%t 3ood/sa3 d%st
.Dpos%re to ha6ardo%s materials s%ch as Araldite and 'ardener
loss o property and atality
)a:or in:%ry
Air poll%tion(local
minor in:%ry
&
+
C
C
C
).I,)
-Proper storage o reactive/Jamma$le materials $ased on the st%dy o )SS - reactivity data and other related .CA-<""* material properties -Availa$ility o fre eDting%isher and fre hydrant -ormation o
Pattern S%pervisor9 Saety Committee
).I,)
-Grade test cond%cted prior to hiring -Saety orientation re?%ired prior to 3ork -Reg%lar meeting is cond%cted(3eekly and monthly -Reg%lar preventive maintenance -Providing PP.s to all .CA-<""# 3orkers -!ong sleeve %niorm provided to 3orkers -esta$lished monitoring o $%sted lamps and immediate replacement -availa$ility o company clinic9 n%rse and trained frst aiders -employees are provided 3ith health card
Pattern S%pervisor9 Saety Committee
).I,)
-%tili6ation o anneD area -d%st collecting pan and container are provided .CA-<"*4 -reg%lar collection o sa3 d%st and c%t 3oods -iss%ance and %sage o PP.
Pattern S%pervisor9 Saety Committee
).I,)
-Chemicals are place near 3indo3 or open area or good ventilation -proper ppe is provided -availa$le spill control materials and .CA-<"5 containment -orientation o concerned personnel on ra3 material )SS -availa$ility o company clinic9 n%rse and trained frst aid team
Pattern S%pervisor9 Saety Committee
Consider installation o d%st collection or eDha%st d%ct to collect generated sa3 d%st>
Pattern S%pervisor9 Saety Committee9 )
"#*
"#*0
"#*&
Pattern and Core$oD Pattern repair Preparation
Pattern and Core$oD Pattern repair Preparation
Pattern and Core$oD Preparation
Penetration o oreign $ody to the eyes
Contact 3ith sharp o$:ects
Checking o gating system9 spr%e pop-o;9
minor in:%ry
in:%ry
Re:ection o casting
*
0
C
+
).I,)
-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program -Preventive maintenance .CA-<"" o machines is done reg%larly -Installation o spray mist -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
Pattern S%pervisor9 Saety Committee
).I,)
-Grade test cond%cted prior to hiring -Saety orientation re?%ired prior to 3ork -Reg%lar meeting is cond%cted(3eekly and monthly -Reg%lar preventive maintenance -Providing PP.s to all .CA-<""# 3orkers -!ong sleeve %niorm provided to 3orkers -esta$lished monitoring o $%sted lamps and immediate replacement -availa$ility o company clinic9 n%rse and trained frst aiders -employees are provided 3ith health card
Pattern S%pervisor9 Saety Committee
).I,)
-Check sheet history or provided to $e flled %p 3henever the pattern %ndergoes repair -proced%re man%al and 3ork instr%ctions are provided -BO 3ith specifed .CA-<"*0 changes on dimensions and markings are given to pattern s%pervisor -remelting o re:ected items -iss%ance o corrective and preventive action to concerned section
H 'ead9 Pattern S%pervisor
Checking o gating system9 spr%e pop-o;9 Penetration o oreign $ody to the eyes riser9 markings9 do3el and 3ooden $oD
"#*1
Pattern and Core$oD Preparation
"#*2
Pattern and Core$oD Application o mold Preparation release agent
"#*4
Pattern and Core$oD Application o mold Preparation release agent
Inhalation o odors/%mes $y 3orkers
Presence o Jame or fre near the 3orking area
"#*5
Pattern and Core$oD Application o mold Preparation release agent
"#"
Pattern and Core$oD .ndorsement o pattern to elayed endorsement Preparation molding area
"##
)old Preparation
Accidental spillage o mold release agent
Checking completeness o pattern parts and Incomplete parts or accessories accessories
minor in:%ry
*
).I,)
-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program -Preventive maintenance .CA-<"" o machines is done reg%larly -Installation o spray mist -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
Respiratory illness
*
C
).I,)
-%se o respirator .CA-<"#5 -reg%lar air ?%ality monitoring
Pattern S%pervisor9 Saety Committee
).I,)
-esignated areas or mold release agent %sed in pattern repair -availa$ility o fre .CA-<""* eDting%ishers and fre hydrant -ormation o
Pattern S%pervisor9 Saety Committee
Pattern S%pervisor9 Saety Committee
!oss o property and atality
&
+
Pattern S%pervisor9 Saety Committee
!and contamination
C
).I,)
-A3areness o the )SS -Specifc area or di;erent material storage -materials are properly .CA-<"#4 la$eled -delivered in tin container --area or the material is contained -provision o spill kits
elayed delivery to c%stomer
0
C
).I,)
-esta$lished lead time/Prod%ction .CA-<"*& Sched%le/Gracea$ility Slip -Pattern inventory os provided
Pattern S%pervisor9 Prod%cton )anager
).I,)
-Pattern check sheet is accomplished prior to endorsement to molding -endorsement slip rom pattern shop and casting tracea$ility slip are accomplished and .CA-<"# received accordingly $y pattern and molding s%pervisors -casting tracea$ility slip and monitoring sheet are iss%ed to each process and accomplished
)olding !eadman9
elay in prod%ction
C
-O%tso%rcing o other :o$s not a$le to $e accomodated $y the patternmaking section -coordinate 3ith c%stomer or delivery date ad:%stment
Overtime %tili6aton
Pattern S%pervisor9 Prod%cton )anager
)olding !eadman9
"#*
"#
"#0
"#&
"#1
"#2
)old Preparation
Preparation o molding $oDesand/or reinorcement str%ck $y alling o$:ect $ars
)old Preparation
Preparation o molding $oDesand/or reinorcement dropping o load rom crane $ars
)old Preparation
Preparation o molding $oDesand/or reinorcement crane overloading $ars
)old Preparation
Preparation o molding $oDesand/or reinorcement s3inging o crane load $ars
)old Preparation
Preparation o molding $oDesand/or reinorcement crane 3heel alling o; its rails $ars
)old Preparation
Preparation o molding Shortage o molding $oDes and/or $oDesand/or reinorcement reinorment $ars $ars
)a:or in:%ry
)a:or in:%ry
)a:or in:%ry/crane damage
)a:or in:%ry
)a:or in:%ry
delay in prod%ction
C
C
C
C
C
C
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and )olding .CA-<""4 orklit saety operation !eadman9 )older -inventory and cheking o molding $oD condition and s%$se?%ent repair
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and )olding .CA-<""4 orklit saety operation !eadman9 )older -inventory and cheking o molding $oD condition and s%$se?%ent repair
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and )olding .CA-<""4 orklit saety operation !eadman9 )older -inventory and cheking o molding $oD condition and s%$se?%ent repair
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and )olding .CA-<""4 orklit saety operation !eadman9 )older -inventory and cheking o molding $oD condition and s%$se?%ent repair
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and )olding .CA-<""4 orklit saety operation !eadman9 )older -inventory and cheking o molding $oD condition and s%$se?%ent repair
).I,)
-Consider gathering data to Gracea$ility sheet iss%ed help in e8cient sched%ling o to molders or the daily Prod%ction items to $e molded> )ake an sched%le o items to $e )anager9 inventory o molding $oDes .CA-<"0& molded o items not a$le to $e -
Prod%ction )anager9
-Perorming cali$ration $eor sanding operation -Panel control indicator lights %p 3hen the %nit is mal%nctioning -reg%lar maintenance o d%st collectors -.S )achine aily .CA-<"#& Check Sheet is accomplised proir to operation -conttrol %sage o chemical -installation o sand reclamation system
)olding !eadman9 )older
"#4
)old Preparation
Sanding operation
%se o chemicals
costly
*
C
).I,)
"#5
)old Preparation
Sanding operation
Improper disposal o 3aste3ater and 3etted d%st rom d%st collector
%npleasant s%rro%ndings
C
).I,)
.CA-<"#1
).I,)
-Provide eDcl%sive compressor %nit or miDer -Cond%ct reg%lar preventive maintenance on chemical p%mps -Accomplish .S )achine aily Check .CA-<"* Sheet -Presence o ork Instr%ction at the 3ork area -Reg%lar addition o ne3 sand -Replace re:ect
).I,)
-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program -Preventive maintenance )olding .CA-<"" o machines is done !eadman9 Saety reg%larly Committee -Installation o spray mist -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
"#0"
"#0#
)old Preparation
)old Preparation
Sanding operation
Sanding operation
Improper cali$ration ratio
incompletely c%red molds9 re:ected molds/castings
minor in:%ry
*
*
.
-aily cleaning o 3ettype d%st collector -%sage o metal container or 3et d%st collection -,se collected 3et d%st sa $ackfll
Consider p%rchase o sieve analysis e?%ipment to monitor and control sand grain si6e and ad:%st resin to sand ratio accordingly>
Consider p%rchase o catalyst/resin $lending machine that ad:%sts catalyst strength $ased on sand temperat%re in order to prod%ce ?%ality molds
)olding !eadman9 )older9 !oader Operator
)olding !eadman9 )older9 )aintenance
"#0*
"#0
"#00
"#0&
)old Preparation
)old Preparation
)old Preparation
)old Preparation
Sanding operation
Sanding operation
Sanding operation
Sanding operation
irect miDing and eDpos%re to chemicals
Person might all do3n 3hen stepping on roller conveyor
orkers might $e hit $y hanging miDer 3hen stepping on conveyor
Skin9 eye9 respiratory digestive tract irritation
.Dplosion/ma:or in:%ry/damage o company property
minor in:%ry
minor in:%ry
minor in:%ry
0
*
*
*
+
).I,)
-Proper la$eling o containers -Posting o 3ork instr%ction at the sand cali$ration area -Chemical containers are located near the 3indo3 or good ventilation -Proper PP. is provided -Spill response materials are availa$le )olding .CA-<"#5 -containment !eadman9 Saety -availa$ility o company Committee clinic 9 n%rse and frst aid team -health card is given to all reg%lar employees maintenance o company property -availa$ility o fre eDting%isher at the 3ork area -Iss%ance o PP.Es
).I,)
-Provision o stair step -&S program is implemented -implementation o &S .CA-<"" program -availa$ility o company clinic -provision o health card or reg%lar employees
).I,)
-isc%ssing incidents d%ring monthly saety meeting -Provision o stair step )olding -'ealth card provided to .CA-<"1 !eadman9 Saety each employee Committee -Availa$ility o company clinic -Grained frst ai der availa$le on 3orking area
).I,)
)olding Availa$ility o hospital 3ithin !eadman9 Saety &km radi%s Committee
-Chemical is placed near the 3indo3 or good ventilation -Proper PP. is provided -availa$le spill contrl materials and )olding containment proced%re .CA-<"5 !eadman9 Saety orientation on concerned Committee personnel on ra3 materials )SS -availa$ility o company clinic9 n%rse9 and frst aid team
)olding !eadman9 Saety Committee
"#01
"#02
"#04
"#05
)old Preparation
)old Preparation
)old Preparation
)old Preparation
Sanding operation
Sanding operation
eDpos%re to silica d%st
eDpos%re to silica d%st
Ramming o sand miDt%re
Ramming o sand miDt%re sot ramming
minor in:%ry (skin and eye irritation
l%ng in:%ry (silicosis
minor in:%ry(eye irritation
3eak mold9 casting re:ection
&
*
*
C
+
.
).I,)
).I,)
-Chemical is placed near the 3indo3 or good ventilation -Proper PP. is provided -availa$le spill contrl materials and )olding containment proced%re .CA-<"5 !eadman9 Saety orientation on concerned Committee personnel on ra3 materials )SS -availa$ility o company clinic9 n%rse9 and frst aid team
-Chemical is placed near the 3indo3 or good ventilation -Proper PP. is provided -availa$le spill contrl materials and )olding containment proced%re .CA-<"5 !eadman9 Saety orientation on concerned Committee personnel on ra3 materials )SS -availa$ility o company clinic9 n%rse9 and frst aid team
).I,)
-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program -Preventive maintenance )olding .CA-<"" o machines is done !eadman9 Saety reg%larly Committee -Installation o spray mist -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
).I,)
-Provide eDcl%sive compressor %nit or miDer -Cond%ct reg%lar preventive maintenance on chemical p%mps -Accomplish .S )achine aily Check .CA-<"* Sheet -Presence o ork Instr%ction at the 3ork area -Reg%lar addition o ne3 sand -Replace re:ect
)olding !eadman9 )older9 )aintenance
Consider p%rchase o catalyst/resin $lending machine that ad:%sts catalyst strength $ased on sand temperat%re in order to prod%ce ?%ality molds
"#&"
"#
"#&*
"#&
)old Preparation
)old Preparation
)old Preparation
)old Preparation
C%ring and stripping o pattern/core$oD and vis%al $ody parts hit $y mallet/hammer inspection
C%ring and stripping o pattern/core$oD and vis%al mold alls d%e to poor liting techni?%e inspection
C%ring and stripping o pattern/core$oD and vis%al mold alls d%e to poor liting techni?%e inspection
C%ring and stripping o pattern/core$oD and vis%al dropping o load rom crane inspection
minor in%ry
minor in:%ry
molds re:ected
ma:or in:%ry
*
*
*
C
C
).I,)
-maintaining sae distance rom items or shakeo%t -esta$lished 3ork instr%ctions .CA-<"0* -modifed handles rom $all type to a more s%ita$le and d%ra$le one -availa$ility o company clinic9 n%rse and trained frst aiders>
)olding !eadman9 )older9 Saety Committee
).I,)
-Crane operatoin seminar is given -%ra$le chain sling is %sed and 3ith strength certifcate provided -reg%lar preventive maintenance o crane .CA-<"#" -daily checklist maintenance o crane -daily checklist o crane is accomplished prior to operation -PP. is provided -Availa$ility o company clinic
)olding !eadman9 )older9 Saety Committee
).I,)
).I,)
-Crane operatoin seminar is given -%ra$le chain sling is %sed and 3ith strength certifcate provided -reg%lar preventive maintenance o crane .CA-<"#" -daily checklist maintenance o crane -daily checklist o crane is accomplished prior to operation -PP. is provided
)olding !eadman9 )older9 Saety Committee
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and orklit saety operation -inventory and cheking o molding $oD condition )olding .CA-<""4 and s%$se?%ent repair !eadman9 )older -reg%lar preventive maintenance o crane and orklit -checklist o crane prior to operation
Remolding
)olding !eadman9 )older
"#&0
"#&&
"#&1
"#&2
)old Preparation
)old Preparation
)old Preparation
)old Preparation
C%ring and stripping o pattern/core$oD and vis%al crane overloading inspection
C%ring and stripping o pattern/core$oD and vis%al s3inging o crane load inspection
C%ring and stripping o pattern/core$oD and vis%al crane 3heel alling o; its rails inspection
Granser o core molds to coating/setting area
getting str%ck $y orklit
)a:or in:%ry/crane damage
ma:or in:%ry
ma:or in:%ry
ma:or in:%ry
C
C
C
C
).I,)
).I,)
).I,)
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and orklit saety operation -inventory and cheking o molding $oD condition )olding .CA-<""4 and s%$se?%ent repair !eadman9 )older -reg%lar preventive maintenance o crane and orklit -checklist o crane prior to operation
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and orklit saety operation -inventory and cheking o molding $oD condition )olding .CA-<""4 and s%$se?%ent repair !eadman9 )older -reg%lar preventive maintenance o crane and orklit -checklist o crane prior to operation
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and orklit saety operation -inventory and cheking o molding $oD condition )olding .CA-<""4 and s%$se?%ent repair !eadman9 )older -reg%lar preventive maintenance o crane and orklit -checklist o crane prior to operation
-competency re?%irement or orklit operator and trade test is cond%cted -seminars and training on orklit saety operation -orklit horn9 $acking )olding alarm and side mirrors !eadman9 .CA-<"# are installed )older9
-Cond%ct
'R9 )aintenance9 Saety Committee
"#&4
"#&5
"#1"
"#1#
)old Preparation
)old Preparation
)old Preparation
)old Preparation
)old coating9 drying and vis%al inspection
)old coating9 drying and vis%al inspection
)old coating9 drying and vis%al inspection
)old coating9 drying and vis%al inspection
dropping ha6ard 3hen liting molds
Alcohol catching fre and eDploding
Skin9 eye9 respiratory digestive tract irritation
minor in:%ry
mold re:ected
ma:or in:%ry9 atality
minor in:%ry
*
*
&
*
C
).I,)
).I,)
'I'
).I,)
-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program -Preventive maintenance .CA-<"" o machines is done reg%larly -Installation o spray mist -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
-Crane operatoin seminar is given -%ra$le chain sling is %sed and 3ith strength certifcate provided -reg%lar preventive maintenance o crane .CA-<"#" -daily checklist maintenance o crane -daily checklist o crane is accomplished prior to operation -PP. is provided
Pattern S%pervisor9 Saety Committee
)olding !eadman9 Remolding )older9 Saety Committee
-Properly designated 3orking areas as ar a3ay rom the melting and po%ring operations as possi$le -sec%re or cover the Coating sol%tion d%ring the Operator9 .CA-<"** po%ring process
-Chemical is placed near the 3indo3 or good ventilation -Proper PP. is provided -availa$le spill control Coating materials and Operator9 containment proced%re .CA-<"5
)olding !eadman9 )older
"#1*
"#1
)old Preparation
)old Preparation
)old coating9 drying and vis%al inspection
)old repair
Ingestion o methanol
atality/$lindness
minor in:%ry
&
*
+
).I,)
-orientation o concerned personnel on ra3 Coating materials )SS Operator9 .CA-<"0" -3earing o provided PP.
).I,)
-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program -Preventive maintenance .CA-<"" o machines is done reg%larly -Installation o spray mist -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
)olding !eadman9 )aintenance9 Saety Committee
"#10
)old Preparation
)old repair
collapse o repaired portion
casting re:ected
*
.
).I,)
-presence o ork Instr%ction in 3ork area )olding -Presence o eDperienced !eadman9 s%pervisor and skiled line .CA-<"
"#1&
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
mismatch/loose clamping
casting re:ected
).I,)
.CA-<"##
"#11
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
)old might all rom crane
mold re:ected
*
).I,)
s%pervision -proper clamping o molds prior to transer -ens%re mold paste has dried prior to transer -reg%lar inventory o
Setting S%pervisor/ Operator
-Re-casting -disc%ss in prod%ction meeting or every ma:or oc%rrence
-Crane operatoin seminar is given -%ra$le chain sling is %sed and 3ith strength certifcate provided -reg%lar preventive Setting maintenance o crane S%pervisor/ .CA-<"#" Remolding -daily checklist Operator9 Saety maintenance o crane Committee -daily checklist o crane is accomplished prior to operation -PP. is provided
)olding !eadman9 )older
"#12
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
.Dpos%re to sparks and splashes
minor in:%ry ($%rns
*
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
-Ho mold re-to%ches $y coating near %rnace d%ring charging operation -saety meeting and .CA-<"** a3areness -coating sol%tion m%st $e sec%red and no coating applications near the area d%ring tapping and po%ring
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
Alcohol catching fre and eDploding
"#15
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
Skin9 eye9 respiratory digestive tract irritation
minor in:%ry
C
).I,)
"#2"
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
dropping o load rom crane
ma:or in:%ry
C
).I,)
.CA-<""4
molding $oDes to approDimately & t> -Seminars on crane and orklit saety operation -inventory and cheking o molding $oD condition
Setting S%pervisor/ Operator
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Setting S%pervisor/ Operator
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Setting S%pervisor/ Operator
"#14
"#2#
"#2*
crane overloading
s3inging o crane load
ma:or in:%ry9 atality
)a:or in:%ry/crane damage
ma:or in:%ry
&
C
C
C
'I'
-availa$le spill control materials and .CA-<"5 containment -orientation o concerned personnel on ra3
Setting S%pervisor/ Operator
Setting S%pervisor/ Operator
)elting Operator9
"#2
"#20
)old Preparation
)old assem$ly9 endorsement o assem$led molds to po%ring and recording o po%red molds
)old Preparation
Assem$led molds are short o set target Receipt o mold assem$ly ?%antity
"#2&
)old Preparation
Preparation o ra3 materials
"#21
)old Preparation
Preparation o ra3 materials
"#22
)old Preparation
Preparation o ra3 materials
crane 3heel alling o; its rails
ma:or in:%ry
astage o electric po3er
C
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
).I,)
-accomplishment o .CA-<"#2 casting tracea$ility slip or each process>
Setting S%pervisor/ Operator
Setting S%pervisor/ Operator9 Coating Operator9 )older9
-competency re?%irement or orklit operator and trade test is cond%cted -seminars and training on orklit saety operation -orklit horn9 $acking alarm and side mirrors
etting str%ck $y orklit
)a:or in:%ry
C
).I,)
%st emission/smoke emission
ill health/ air pol%tion
*
C
).I,)
-%se o respirator .CA-<"#5 -reg%lar air ?%ality monitoring
)elting !eadman/ Operator9 Saety Committee
).I,)
-Grade test cond%cted prior to hiring -Saety orientation re?%ired prior to 3ork -Reg%lar meeting is cond%cted(3eekly and monthly -Reg%lar preventive maintenance -Providing PP.s to all .CA-<"" 3orkers -!ong sleeve %niorm provided to 3orkers -esta$lished monitoring o $%sted lamps and immediate replacement -availa$ility o company clinic9 n%rse and trained frst aiders -employees are provided 3ith health card
)eltin g !eadman/ Operator9 Saety Committee
)inor in:%ry
*
-Cond%ct
'R9 )aintenance9 Saety Committee
"#24
"#25
"#4"
"#4#
)old Preparation
)old Preparation
)old Preparation
)old Preparation
)etal charging
)etal charging
)etal charging
)etal charging
Potential eDplosion
Penetration o metal to cooling system ca%sing eDplosion
,se o electricity or the %rnace
,se o ra3 material(scrap
Single to m%ltiple atality
Single to m%ltiple atality/ loss o property
epletion o reso%rces/ high prod%ction costs
epletion o reso%rces
&
&
+
+
).I,)
-shaded scrap area to avoid 3et metal charges +aling Operator9 -material segregation and P%rchasing 9 presence o $aling areho%se9 .CA-<"*1 machine )elting -accredited scrap !eadman/ s%pplier operator
).I,)
-order lining materials only rom accredited s%pplier -Operator on-the-:o$ training -monitor n%m$er o heats per lining installation -$%ilt-in sensor on the )elting %rnace lining that can !eadman/ Presence o another %rnace detect penetration Operator9 .CA-<""0 3hich can $e %sed -preventive maintenance )ainenance immediately cond%cted reg%lalry Personnel9 Saety -electric %rnace Committee monitoring sheet is accomplished every charge -orientation o melting operator vis-a-vis %rnace maintenance and operation
).I,)
-periodic preventive maintenance o %rnaces -daily checksheet or electric %rnace monitoring -skilled operator/ presence o 3ork instr%ction -$aled steel scrap to hasten cahrging and melting -accomplishment o .CA-<"#2 casting tracea$ility slip or each process> -preventive maintenance o crane and other machines -revie3 o previo%s perormance d%ring epartmental )eeting -Contin%o%s melting operation -monitoring kh per kg o metal
)elting !eadman/ Operator9 )aintenance9
).I,)
-prod%ction sched%ling $ased on c%tomer re?%irement and stock level -%se o casting tracea$ility slip -esta$lished cost .CA-<"*" red%ction program thro%gh revie3 o monthly inventory and cons%mption reports -recycling o metal splashes and fns -remelting o re:ect castings
)elting !eadman/ Operator9
)elting !eadman/ Operator9
"#4*
"#4
"#40
"#4&
"#41
)old Preparation
)old Preparation
)old Preparation
)old Preparation
)old Preparation
)etal charging
)etal charging
)etal charging
)etal charging
)etal charging
Smoke emission (%rnace
.Dpos%re to sparks and splashes
dropping o load rom crane
s3inging o crane load
crane 3heel alling o; its rails
air p%ll%tion/ minor discomort
+%rns9 minor in:%ry
ma:or in:%ry
ma:or in:%ry
ma:or in:%ry
*
*
C
C
C
C
)elting !eadman/ Operator9 )aintenance9 Saety Committee9 Poll%tion Control O8cer
).I,)
-d%st hood is installed -se o masks and .CA-<"#5 respirators -reg%lar air ?%ality monitoring
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
)elting !eadman/ Operator
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
)elting !eadman/ Operator
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
)elting !eadman/ Operator
)elting Operator9
"#42
"#44
"#45
)old Preparation
)old Preparation
)old Preparation
)etal charging
.Dpos%re to sparks and splashes
Checking the composition ,se o electricity or the %rnace d%ring o molten metal holding time
Checking the composition .Dpos%re to sparks and splashes o molten metal
+%rns9 minor in:%ry
depletion o reso%rces
+%rns9 minor in:%ry
*
*
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
).I,)
-periodic preventive maintenance o %rnaces -daily checksheet or electric %rnace monitoring -skilled operator/ presence o 3ork instr%ction -$aled steel scrap to hasten cahrging and melting -accomplishment o .CA-<"#2 casting tracea$ility slip or each process> -preventive maintenance o crane and other machines -revie3 o previo%s perormance d%ring epartmental )eeting -Contin%o%s melting operation -monitoring kh per kg o metal
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
)elting Operator9
)elting !eadman/ Operator9 )aintenance9
)elting Operator9
"#5"
"#5#
"#5*
)old Preparation
)old Preparation
)old Preparation
Preheating o ladles
Preheating o ladles
Preheating o ladles
Smoke emission
dropping o load rom crane
s3inging o crane load
air poll%tion
ma:or in:%ry
ma:or in:%ry
*
C
C
C
)elting !eadman/ Operator9 )aintenance9 Saety Committee9 Poll%tion Control O8cer
).I,)
-d%st hood is installed -se o masks and .CA-<"#5 respirators -reg%lar air ?%ality monitoring
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
)elting !eadman/ Operator
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
)elting !eadman/ Operator
)elting !eadman/ Operator
"#5
)old Preparation
Preheating o ladles
crane 3heel alling o; its rails
ma:or in:%ry
C
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
"#50
)old Preparation
Chill testing
hard casting
).I,)
.CA-<"0
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
"#5&
)old Preparation
Chill testing
.Dpos%re to sparks and splashes
+%rns9 minor in:%ry
*
-presence o 3ork instr%ction in the 3orking area
)elting !eadman/ Operator
Replace re:ected casting
)elting Operator9
"#51
)old Preparation
Gemperat%re checking
Gemperat%re too high
astage o reso%rces and electricity
C
).I,)
-Replace thermoco%ple -re-charge periodically -presenceo 3ork instr%ctoin and standard temperat%re .CA-<"& -reg%lar eDternal cali$ratoin o pyrometer -orientation o concerned 3orkers regarding the handling o pyrometer
"#52
)old Preparation
Charging o inoc%lant/ spheroidi6er
3rong se?%ence o chraging
hard casting
).I,)
Predsence o 3ork .CA-<"0 instr%ction in the 3orking area
"#54
)old Preparation
"#55
)old Preparation
"*""
)old Preparation
Charging o inoc%lant/ spheroidi6er
.Dpos%re to sparks and splashes
Gapping molten metal into )etal spillage rom the ladle the ladle
Gapping molten metal into .Dpos%re to sparks and splashes the ladle
)elting !eadman/ Operator9 FC Inspector
-S3itch o; %rnace po3er -ait or temperatre to go do3n
+%rns9 minor in:%ry
*
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
)a:or in:%ry
0
C
).I,)
-provide in-ho%se training )elting or m elter/po%rer !eadman/ .CA-<"*2 -reg%lar claning and Operator9 Po%ring replacement o ladle Operator lining
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
+%rns9 minor in:%ry
*
)elting !eadman/ Operator9
)elting Operator9
)elting Operator9
"*"#
"*"*
"*"
"*"0
)old Preparation
)old Preparation
)old Preparation
)old Preparation
Po%ring molten metal into )olten metal r%no%t rom the mold molds
Po%ring molten metal into !adle collapsing rom crane molds
Po%ring molten metal into Po%ring at high temperat%re molds
Po%ring molten metal into Po%ring $elo3 the standard po%ring molds temperat%re
temporary disa$ility9 re:ected castings
Sand %sion9 Re:ected castings
Re:ected castings
*
&
+
C
).I,)
-esta$lished 3ork instr%ctions to ens%re consistent mold strength -correct and proper gating system -do3el dimension is Setting checked S%pervisor/ -mold paste eval%ated $y Operator9 Po%ring .CA-<""& FIG and approved or %se Operator9 -reg%lar checking o
).I,)
-a3areness o cranes maDim%m capacity -ladle has di;erent si6e Setting according to capacity S%pervisor/ -reg%lar preventive Operator9 )elting maintenance o crane !eadman/ .CA-<""1 -training on crane saety Operator9 Po%ring operation Operator9 -checklist or crane prior
).I,)
-Replace thermoco%ple -re-charge periodically -presenceo 3ork instr%ctoin and standard temperat%re .CA-<"& -reg%lar eDternal cali$ratoin o pyrometer -orientation o concerned 3orkers regarding the handling o pyrometer
).I,)
-presence o 3ork instr%ctions on the 3ork area -ladle preheating -checking and meeting re?%ired temperat%re .CA-<""2 $eore tapping -making m%ltiple-cavity patternsor small items -remelting -disc%ssion on re:ection incl%ded in 3eekly prod%ction meeting
)elting !eadman/ Operator9 FC Inspector
Setting S%pervisor9 Po%ring Operator9 )elting !eadman/ Operator9
ait or temperat%re to go do3n
Po%ring Operator9
"*"&
"*"1
"*"2
"*"4
"*"5
"*#"
)old Preparation
)old Preparation
)old Preparation
)old Preparation
)old Preparation
)old Preparation
Po%ring molten metal into dropping o load rom crane molds
Po%ring molten metal into s3inging o crane load molds
Po%ring molten metal into crane 3heel alling o; its rails molds
Po%ring molten metal into .Dpos%re to sparks and splashes molds
.ndorsement o po%red molds to shakeo%t
.ndorsement o po%red molds to shakeo%t
dropping o load rom crane
s3inging o crane load
ma:or in:%ry
ma:or in:%ry
ma:or in:%ry
+%rns9 minor in:%ry
ma:or in:%ry
ma:or in:%ry
*
C
C
C
C
C
).I,)
-'eight limit o storing molding $oDes to approDimately & t> Setting -Seminars on crane and S%pervisor/ .CA-<""4 orklit saety operation Operator9 Po%ring -inventory and cheking o Operator molding $oD condition and s%$se?%ent repair
).I,)
-'eight limit o storing molding $oDes to approDimately & t> Setting -Seminars on crane and S%pervisor/ .CA-<""4 orklit saety operation Operator9 Po%ring -inventory and cheking o Operator molding $oD condition and s%$se?%ent repair
).I,)
-'eight limit o storing molding $oDes to approDimately & t> Setting -Seminars on crane and S%pervisor/ .CA-<""4 orklit saety operation Operator9 Po%ring -inventory and cheking o Operator molding $oD condition and s%$se?%ent repair
).I,)
-provide cover or Jo3 coat machine to $e %sed d%ring po%ring -esta$lished 3ork instr%ction or mold Setting assem$ly 3hich incl%des S%pervisor/ preheating o molds Operator9 Po%ring $eore setting Operator9 )elting -esta$lished 3ork Re:ect poor ?%ality scrap pr Operator9 .CA-<"0# instr%ction or scrap ret%rns that may ca%se Coating press 3hich incl%des splashing 3hen charged Operator9 saekeeping o prepared
).I,)
-'eight limit o storing molding $oDes to approDimately & t> Setting -Seminars on crane and S%pervisor/ .CA-<""4 orklit saety operation Operator9 Po%ring -inventory and cheking o Operator molding $oD condition and s%$se?%ent repair
).I,)
-'eight limit o storing molding $oDes to approDimately & t> Setting -Seminars on crane and S%pervisor/ .CA-<""4 orklit saety operation Operator9 Po%ring -inventory and cheking o Operator molding $oD condition and s%$se?%ent repair
)elting Operator9
"*##
)old Preparation
.ndorsement o po%red molds to shakeo%t
crane 3heel alling o; its rails
ma:or in:%ry
C
).I,)
-'eight limit o storing molding $oDes to approDimately & t> Setting -Seminars on crane and S%pervisor/ .CA-<""4 orklit saety operation Operator9 Po%ring -inventory and cheking o Operator molding $oD condition and s%$se?%ent repair
"*#*
)old Preparation
.val%ating %rnace condition
.Dpos%re to silica d%st (reractory
silicosis
&
+
).I,)
.CA-<"5
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Shakeo%t Operator
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Shakeo%t Operator
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Shakeo%t Operator
Shakeo%t Operator
-provision o proper PP.
)old Preparation
Receipt o po%red molds and eDtraction o castings dropping o load rom crane rom molds
)old Preparation
Receipt o po%red molds and eDtraction o castings s3inging o crane load rom molds
)old Preparation
Receipt o po%red molds and eDtraction o castings crane 3heel alling o; its rails rom molds
"*#1
)old Preparation
Receipt o po%red molds and eDtraction o castings crane overloading rom molds
)a:or in:%ry/crane damage
C
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
"*#2
)old Preparation
Receipt o po%red molds and eDtraction o castings .Dpos%re to silica d%st (reractory rom molds
silicosis
&
+
).I,)
.CA-<"5
-provision o proper PP.
"*#4
)old Preparation
Receipt o po%red molds and eDtraction o castings .Dpos%re to silica d%st (reractory rom molds
minor in:%ry
C
).I,)
.CA-<"5
-provision o proper PP.
"*#
"*#0
"*#&
ma:or in:%ry
ma:or in:%ry
ma:or in:%ry
C
C
C
"*#5
"**"
"**#
"***
)old Preparation
)old Preparation
)old Preparation
)old Preparation
Receipt o po%red molds and eDtraction o castings $ody parts hit $y mallet/hammer rom molds
Removal o adhering sand dropping o load rom crane rom the castings
Removal o adhering sand s3inging o crane load rom the castings
Removal o adhering sand crane 3heel alling o; its rails rom the castings
minor in:%ry
ma:or in:%ry
ma:or in:%ry
ma:or in:%ry
*
C
C
C
C
).I,)
-maintaining sae distance rom items or shakeo%t -esta$lished 3ork instr%ctions .CA-<"0* -modifed handles rom $all type to a more s%ita$le and d%ra$le one -availa$ility o company clinic9 n%rse and trained frst aiders>
)olding !eadman9 )older9 Saety Committee
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Shakeo%t Operator
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Shakeo%t Operator
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
Shakeo%t Operator
Shakeo%t Operator
"**
)old Preparation
Removal o adhering sand crane overloading rom the castings
)a:or in:%ry/crane damage
C
).I,)
-'eight limit o storing molding $oDes to approDimately & t> -Seminars on crane and .CA-<""4 orklit saety operation -inventory and cheking o molding $oD condition and s%$se?%ent repair
"**0
)old Preparation
Receipt o po%red molds and eDtraction o castings .Dpos%re to silica d%st (reractory rom molds
minor in:%ry
C
).I,)
.CA-<"5
-provision o proper PP.
l%ng in:%ry (silicosis
&
+
).I,)
.CA-<"5
-provision o proper PP.
"**&
Receipt o po%red molds Shakeo%t and Cleaning and eDtraction o castings .Dpos%re to silica d%st (reractory rom molds
"**1
"**2
"**4
"**5
Shakeo%t and Cleaning
Shakeo%t and Cleaning
Shakeo%t and Cleaning
'ammering o; eDcess metal on the casting
'ammering o; eDcess metal on the casting
'ammering o; eDcess metal on the casting
Granser o sand/l%mps to Shakeo%t and Cleaning sand stock area and primary $lasting
+ody parts hit $y chips or other casting parts d%ring hammering
%st and %me emission
minor in:%ry
minor in:%ry
minor in:%ry
ill health/locali6ed air poll%tion
*
*
*
*
C
).I,)
-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program -Preventive maintenance Shakeo%t .CA-<"" o machines is done Operator9 Saety reg%larly Committee -Installation o spray mist -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
).I,)
-maintaining sae distance rom items or shakeo%t -esta$lished 3ork instr%ctions .CA-<"0* -modifed handles rom $all type to a more s%ita$le and d%ra$le one -availa$ility o company clinic9 n%rse and trained frst aiders>
Shakeo%t Operator9 Saety Committee
).I,)
-,se o PP. to protect or .CA-<"01 minimi6e the orce rom Jying o$:ects
-Consider %se o hard plastic ace shields or operators that perorm hammering activities Shakeo%t -esta$lish sae distance that Operator9 Saety operators other than the one Committee doing the hammering sho%ld $e at d%ring s%ch activities -install dividers
).I,)
-preventive maintenance o machines -reg%lar maintenance o +lastin )achine d%st collector Operator9 -%se o ind%strial an .CA-<"#* )aintenance9 -d%st masks and earpl%gs Saety are iss%ed to employees Committee -reg%lar disposal o d%st in the d%st collector machine
Saety Committee
"*"
Granser o sand/l%mps to Shakeo%t and Cleaning sand stock area and primary $lasting
minor in:%ry
C
).I,)
"*#
Granser o sand/l%mps to Shakeo%t and Cleaning sand stock area and primary $lasting
Slipping d%e to steel shot $alls/ sand l%mps minor in:%ry on the Joor
*
C
).I,)
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-Ade?%ate implementation o 3earing PP.> Proper selection o PP. or di;erent nat%res o 3ork in the plant -ood 'o%sekeeping program +lastin )achine -Preventive maintenance Operator9 .CA-<"" o machines is done )aintenance9 reg%larly Saety -Installation o spray mist Committee -Spraying o 3ater on Joor t3ice daily -installation o dividers at grinding area -availa$ility o company clinic9 n%rse and frst aid team
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