HIRA1

Format No.
: F-MR-024
JCB India Ltd., Jaipur Rev. No.:01
Hazard Identification and Risk Assessment Issue Date: 05.06.2019
Scissor-Production Prepared By :Manisha Kumawat / Pushpanshu Singh Date :20/10/2022 Approved By:Aniwarj kumar
Legends:
D = Direct, I = Indirect, V=Visitor
R = Routine, NR = Non-Routine
Condition: N = Normal, A = Abnormal, E = Emergency , L = Legal
R.L. = Risk Level (1 = Trivial, 2 = Acceptable, 3 = Moderate, 4 = Substantial, 5 = Intolerable)
S=Significant, NS=Non Significant
Severity Probability Risk Level Table
H 3 4 5
H - High - Fatal /Permanent Disability H - High - Will Happen
Probability
M 2 3 4
M - Medium - Medical Aid Injury - May/ Can Happen L 1 2 3

M - Medium
- Has been Observed L M H
- Rare Chances Risk Level

L - Low - First Aid Injury L - Low Severity
- Never Happened
Department: Access Scissor Production
Severity Probablility
R/ Hazard / Applicable Risk
S No. Activity / Sub Activity D/I/V N/A/E/L Explanati Risk Existing Control S/NS Proposed Control Opportunity Remarks
NR Concern Legal Req. Explanation H/M/L H/M/L Level
on
Brake hub & CWT fitment
Fall hazard, can fall on Hand & Leg May/Can Lifting tool modification required for
45 Brake hub lifting D R N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS Modification done IMP Closed
Leg / hand injury Happen use
Tool may slip and injured to Hand & Leg May/Can

46 Brake hub mtg D R N NA L M 2 Man Hour Losses Trained operator NS
operator injury Happen
Tool may slip and injured to Hand & Leg May/Can

47 Brake hub adaptor & hose tigtening D R N NA L M 2 Man Hour Losses Trained operator NS Fixed torque wrench required New tool ordered IMP Open
Fall hazard, can fall on Hand & Leg May/Can
48 CWT lifting D R N NA M M 3 Man Hour Losses Trained operator, Magnet for lifting NS
Leg / hand injury Happen
Tool may slip and injured to Hand/Finger May/Can
49 CWT mtg and torquing D R N NA L M 2 Man Hour Losses Trained operator NS
Chassis door and latch fitment
Fall hazard, can fall on Hand/Finger May/Can
50 Door lifting with sling D R N NA M M 3 Man Hour Losses Trained operator & Anti Pinch gloves usage NS
Leg / hand Leg injury Happen
Door will come with
Tool may slip and injured to Hand/Finger May/Can Chassis & door should come fitted chassis from
51 Door & pin mtg fitment D R N NA L M 2 Man Hour Losses Trained operator NS IMP Closed
operator injury Happen together from supplier supplier PIP
approved
52 Split pin bending D R N NA L M 2 Man Hour Losses Trained operator NS
53 Door latch assembly D R N NA L M 2 Man Hour Losses Trained operator NS
54 Door stopper & guided box assembly D R N NA L M 2 Man Hour Losses Trained operator NS
Linkage and Pothole bar assembly
55 Linkage assembly D R N NA L M 2 Man Hour Losses Trained operator NS
57 Split pin fitment on chassis D R N NA L M 2 Man Hour Losses Trained operator NS
58 Pothole plate lifting D R N NA M M 3 Man Hour Losses Trained operator & anti pinch gloves usage NS Pothole plate tackle required IMP Open
Hand/Finger May/Can
59 Pothole plate Dropping on chassis D R Hand/Figure injury N NA L M 2 Man Hour Losses Trained operator NS
injury Happen
Hand/Finger May/Can
60 Pothole plate pin mtg & split pin mtg D R Hand/Figure injury N NA L M 2 Man Hour Losses Trained operator NS
injury Happen
Steering cylinder assembly
58 Steering cylinder mounting thread taping D R N NA L M 2 Man Hour Losses Trained operator NS
Fall hazard, can fall on Hand/Finger May/Can Tackle required for steering cylinder New tackle
59 Sterring Cylinder lifting D R N NA M M 3 Man Hour Losses Trained operator & anti pinch gloves usage NS IMP Closed
Leg / hand injury Happen lifting provided
60 Steering Cylinder Fitment D R N NA L M 2 Man Hour Losses Trained operator NS
61 Steering Linkage mounting D R N NA L M 2 Man Hour Losses Trained operator NS
Hand/Finger May/Can Pneumatic hammer
62 Bush Pressing D R Hand / Finger Injury N NA L M 2 Man Hour Losses Trained operator NS Bush pressing tool required. IMP Open
injury Happen to be trial
Wheel carrier assembly
63 Wheel carrier lifting D R N NA M M 3 Man Hour Losses Trained operator & anti pinch gloves usage NS
Hand/Finger May/Can Trained operator & OPL has been given to

64 Wheel Carrier Fitment D R Hand/Figure injury N NA L M 2 Man Hour Losses NS
injury Happen team for Tightening the bolt with washer.
Traction Motor Assembly
Fall hazard, can fall on Hand/Finger May/Can Traction motor tackle modification New tackle
63 Traction Motor lifting D R N NA M M 3 Man Hour Losses Trained operator & anti pinch gloves usage NS IMP Closed
Leg / hand injury Happen required provided
64 Traction Motor bolt Fitment D R N NA L M 2 Man Hour Losses Trained operator NS
Wheel assembly
63 Wheel lifting D R N NA M M 3 Man Hour Losses Trained operator & anti pinch gloves usage NS
64 Wheel Fitment , pin mtg & torquing D R N NA L M 2 Man Hour Losses Trained operator NS
Inversion
Fall hazard, can fall on May/Can
65 Set tool for model wise D R N NA Hand/Leg injury L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
Leg / hand Happen
Hand/Finger May/Can
66 Set programme in system for model wise D R Hit & Fall hazard N NA L M 2 Man Hour Losses Trained Operator NS
injury Happen
Hand/Finger May/Can
67 Move inversion system for anticlock wise D R Hit & Fall hazard N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
injury Happen
68 Tool fixed in chassis D R N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
69 Chassis Lifting D R N NA M M 3 Man Hour Losses Trained operator & anti pinch gloves usage NS
70 Fixed latch lock D R N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
71 Move chassis clockwise D R N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
Hand/Finger May/Can
72 Conveyor stopped D R Hit & Fall hazard N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
injury Happen
Trained operator & anti pinch gloves usage
Hand/Finger May/Can
73 Move chassis to conveyor D R Hit & Fall hazard N NA L M 2 Man Hour Losses and sensor imposed for inversion NS
injury Happen
movement.
74 Chassis dropping D R N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
75 Lock Release manully D R N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
Hand/Finger May/Can
76 Inversion system move to home position D R Hit & Fall hazard N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
injury Happen
Electrical door assemble
Hand / finger May/Can
77 Door Beeding fitment D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
78 Harness Routing/ fitment D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
Fall hazard, can fall on Hand/ Leg May/Can Battery trolley modification required
79 Battery Lifting & Dropping D R N NA M M 3 Man Hour Losses Trained operator & anti pinch gloves usage NS Trolley modified IMP Closed
Leg / hand Injury Happen in one trolley.
Tool may slip and injured to Hand / finger May/Can
80 Door & Chassis Tapping D R N NA L M 2 Man Hour Losses Trained operator NS
operator Injury Happen
81 Fuse bracket fitment D R N NA L M 2 Man Hour Losses Trained operator NS
82 Discon plug and Isolator handle Fitment D R N NA L M 2 Man Hour Losses Trained operator NS
83 DC Contactor Fitment D R N NA L M 2 Man Hour Losses Trained operator NS
Fall hazard, can fall on Hand / finger May/Can
84 Battery Charger lifting and dropping D R N NA L M 2 Man Hour Losses Trained operator & anti pinch gloves usage NS
Leg / hand Injury Happen
85 All Connection fitment D R Hand / finger Injury N NA M M 3 Man Hour Losses Trained operator NS
Injury Happen
86 Pothole sensor fitment D R N NA L M 2 Man Hour Losses Trained operator NS
87 Door Lock Setting D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
88 All connection torque D R N NA L M 2 Man Hour Losses Trained operator NS
Child Part Asemble
Trained operator & anti pinch gloves usage ,
Hand / finger May/Can Special tool required for bush new concept for
89 Bush Pressing D R Hand / finger Injury N NA L M 2 Man Hour Losses dolly implement done but dolly pressed by NS IMP Open
Injury Happen pressing bush press
mallet.
90 Chassis Tapping D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
91 Offline RCBO Box and limit switch sub assembly D R N NA L M 2 Man Hour Losses Trained operator NS
92 Rcbo box mounting and connection D R N NA L M 2 Man Hour Losses Trained operator NS
93 Tilt sensor & retain strip mounting and connection D R N NA L M 2 Man Hour Losses Trained operator NS
94 Limit Switch mounting and connection D R N NA L M 2 Man Hour Losses Trained operator NS
95 Warning light mounting and connection D R N NA L M 2 Man Hour Losses Trained operator NS
96 Wheel carrier , grease nipple and cap fitment D R N NA L M 2 Man Hour Losses Trained operator NS
97 Harness and hoses routing including cable tie D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
98 Chassis emergency cover / bracket fitment D R N NA L M 2 Man Hour Losses Trained operator NS
Hydraulic Door Assemble
99 Offline Pressing plate sub assembly D R N NA L M 2 Man Hour Losses Trained operator NS
100 Offline Ground controller plate subassembly D R N NA L M 2 Man Hour Losses Trained operator NS
101 Offline Tank sub assembly D R N NA L M 2 Man Hour Losses Trained operator NS
102 Door / chassis tapping D R N NA L M 2 Man Hour Losses Trained operator NS
103 Door Beeding fitment D R N NA L M 2 Man Hour Losses Trained operator NS
Fall hazard, can fall on Hand / finger May/Can Trained operator and anti pinch gloves
104 Motor and mvb lifting & dropping D R N NA L M 2 Man Hour Losses NS
Leg / hand /Leg Injury Happen usage
105 Motor Fitment D R N NA L M 2 Man Hour Losses Trained operator NS
106 Pressing plate lifting and dropping D R N NA L M 2 Man Hour Losses NS
Leg / hand /Leg Injury Happen usage
107 Pressing plate / ground controller mounting D R N NA L M 2 Man Hour Losses Trained operator NS
108 Ground controller plate connection D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
109 Tank Lifting and dropping D R N NA L M 2 Man Hour Losses NS
Leg / hand Injury Happen usage
110 Tank mounting D R N NA L M 2 Man Hour Losses Trained operator NS
111 ECU mounting D R N NA L M 2 Man Hour Losses Trained operator NS
112 Filter mounting D R N NA L M 2 Man Hour Losses Trained operator NS
113 MVB Fitment D R N NA L M 2 Man Hour Losses Trained operator NS
114 MVB Hose connection D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
115 Filter adapter mounting D R N NA L M 2 Man Hour Losses Trained operator NS
116 Filter hose connection D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
117 Tank Hose connection D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
118 Fuse bracket fitment D R N NA L M 2 Man Hour Losses Trained operator NS
119 Pothole sensor fitment D R N NA L M 2 Man Hour Losses Trained operator NS
120 Harness Rounting D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
121 Electrical all Connection D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
Scissor Pack Fitment
122 Scissor pack lifting and dropping D R N NA M M 3 Man Hour Losses NS
Leg / hand Injury Happen usage and 2 feet tool usage.
New Pneumatic
Hand / finger May/Can Trained operator & mallet usage for pivot
123 Scissor Pack pivot pin assemble D R Hand / finger Injury N NA L L 2 Man Hour Losses NS Pivot pin assemble tool required hammer trial to be IMP Open
Injury Happen pin assemble.
taken
124 Scissor pack lift for safety stud mounting D R N NA M M 3 Man Hour Losses Trained operator NS
Scissor pack routing
125 Scissor pack T adapter Sub assembly offline D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
126 Hose and harness routing with cable tie D R Hit & Fall hazard N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
RAM Fitment
127 LVB Sub assembly D R N NA L M 2 Man Hour Losses Trained operator NS
128 RAM Lifting & droping D R N NA M M 3 Man Hour Losses NS
Leg / hand Injury Happen usage and 2 feet tool usage.
Hand / finger May/Can Trained operator & Special tool provided for
129 LOWER RAM Rotation D R Hand / finger Injury N NA L M 2 Man Hour Losses NS
Injury Happen ram rotation.
130 RAM Mounting in scissor pack. D R N NA L M 2 Man Hour Losses Trained operator NS
131 Pivot Pin Lifting D R N NA L M 2 Man Hour Losses Trained operator NS
Hand / finger May/Can Trained operatorv and holding tool provided
132 Pivot Pin Assemble in scissor pack and ram. D R Hand / finger Injury N NA L M 2 Man Hour Losses NS
Injury Happen for pivot pin .
133 Emergency wire & hose connection. D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
Charger socket assemble
134 Charger Socket Fitment D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
Counter Weight & U Plate assemble - 1530 ,
1930 , 2032 , 2632
135 Counter weight & ladder lifting & Droping D R N NA Hit /Fall Hazard L M 2 Man Hour Losses Trained operator & Anti pinch gloves usage NS
Leg / hand Happen
136 Counter weight & ladder fitment D R Hand & Finger Injury N NA L M 2 Man Hour Losses Trained operator & Anti pinch gloves usage NS
Injury Happen
137 U-Plate Lifting & Droping D R N NA Hit /Fall Hazard L M 2 Man Hour Losses Trained operator & Anti pinch gloves usage NS
Leg / hand Happen
138 U-Plate fitment D R Hand & Finger Injury N NA L M 2 Man Hour Losses Trained operator & Anti pinch gloves usage NS
Injury Happen
Counter weight assemble - 2646 , 3246 , 4046 ,
4550
Trained operator & Anti pinch gloves usage
139 Counter weight lifting & Droping D R N NA Hit /Fall Hazard L M 2 Man Hour Losses and Counter weight assemble by forklift with NS
Leg / hand Happen
tackle.
Trained operator & Anti pinch gloves usage
May/Can
140 Counter weight fitment by forklift. D R Hit & Fall hazard N NA Hit /Fall Hazard L M 2 Man Hour Losses and Counter weight assemble by forklift with NS
Happen
tackle.
Offline Ladder Fitment - 2646, 3246, 4046 &
4550
no offline (PIP
Fall hazard, can fall on May/Can Trained operator & Anti pinch gloves usage Offline ladder fitment Lifting
141 Ladder Lifting & Droping D R N NA Hit /Fall Hazard M M 3 Man Hour Losses NS raised for lifting IMP Open
Leg / hand Happen and ladder lifting by hand. equipment required
point ) is in process

142 Ladder Fitment D R Hand & Finger Injury N NA L M 2 Man Hour Losses Trained operator & Anti pinch gloves usage NS
Injury Happen
Platfrom Fitment
Fall hazard, can fall on May/Can Trained operator and anti pinch gloves
143 Platfrom Lifting & Dropping D R N NA Hit /Fall Hazard M M 3 Man Hour Losses NS
Leg / hand Happen usage and 2 feet tool usage.
Tool may slip and injured to Hand / finger May/Can Trained operator and anti pinch gloves
144 Platfrom MTG block fitment D R N NA L M 2 Man Hour Losses NS
operator Injury Happen usage and 2 feet tool usage.
Platform power socket assemble
145 Platform power Socket Fitment D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained operator NS
Injury Happen
May/Can
146 Platform power Socket Fitment D R Hit & Fall hazard N NA Hit /Fall Hazard L M 2 Man Hour Losses Trained operator NS
Happen
Flashing & Roll Off
147 Programme Flash in machine D R Hand / finger Injury N NA L M 2 Man Hour Losses Trained Operator NS
Injury Happen
May/Can Anti skid stopper required on roll off
148 Machine move in Calibration Area D R Hit & Fall hazard N NA Hit /Fall Hazard M M 3 Man Hour Losses Trained Operator (IPAF Trained) NS Stopper provided IMP Closed
Happen platform.
Calibration Process
Machine drive from base Medical Aid May/Can Trained Operator (IPAF Trained) & 2 feet
149 0º / 3º Testing D R N M L 2 Man Hour Losses NS
may hit. injury Happen rule complainces
Finger may trap and make Hand & Finger May/Can Trained Operator (IPAF Trained) & Anti
150 Angle sensor & Tilt sensor testing D R N M L 2 Man Hour Losses NS
injury injury. Happen Pinch Gloves usage
Finger may trap and make Medical Aid May/Can Trained Operator (IPAF Trained) & Anti
151 Limit Switch testing - upper /lower D R N M L 2 Man Hour Losses NS
injury injury Happen Pinch Gloves usage
Machine may hit incase of Medical Aid May/Can Trained Operator (IPAF Trained) & Safety
152 Height Testing D R N M L 2 Man Hour Losses NS
functional failure injury Happen stud usage
Machine may hit incase of Medical Aid May/Can
153 Weight Testing - load /no load D R N M L 2 Man Hour Losses Trained Operator (IPAF Trained) NS
functional failure injury Happen
May/Can Trained Operator & Anti Pinch Gloves
154 Weight Lifting & Droping D R Hit & Fall hazard N Hit /Fall Hazard M L 2 Man Hour Losses NS
Happen Usage
155 Speed Testing D R N M L 2 Man Hour Losses NS
Trained Operator (IPAF Trained) &
Medical Aid May/Can
156 Gradeability testing D R Machine May slip and hit. N M L 2 Man Hour Losses Monitoring increased by help of Grid NS
injury Happen
Checksheet by TL
157 Gradeability testing D R N M L 2 Man Hour Losses NS
Revision History
S.No Revision No: Revision details Date
1 1 Severity explanations updated 30.01.2019
2 2 Fixture revised with secondary stopper protection - IMP Closed
3 3 Pneuamtic tool provided - IMP Closed
4 4 Detachable platform provided at station so that small height operator can easily perfrom the given task - IMP Closed
5 5 Complete HIRA reviewed and occurrence revised for 3 significant hazards.
6 6 Complete HIRA Revised and 17 significant hazards identified and 6 Are closed and 11 are open. 20.10.2022
Summary Condition For Significant(S):

1. Total nos. of Significant Risk 3 1.If the Risk Level number is more than 3
2. Total nos. of OCP 2.All Emergency and legal concerns
3. Total improvement projects undertaken 3 3.Flaura & Fauna
Harness Connection , Ram Fitment ,
4. Top 3 Significant Risk
Chassis trolley placement
-
-
Format No.: F-MR-024
JCB India Ltd., Jaipur Rev. No.:02
Hazard Identification and Risk Assessment Issue Date: 05.06.2019
IT- Prepared By : Date : Approved By:
Legends:
D = Direct, I = Indirect, V=Visitor
R = Routine, NR = Non-Routine
Condition: N = Normal, A = Abnormal, E = Emergency , L = Legal
R.L. = Risk Level (1 = Trivial, 2 = Acceptable, 3 = Moderate, 4 = Substantial, 5 = Intolerable)
S=Significant, NS=Non Significant
Severity Probability Risk Level Table
H 3 4 5
Probability
H - High - Fatal /Permanent Disability H - High - Will Happen
M 2 3 4
- May/ Can Happen L 1 2 3

M - Medium - Medical Aid Injury M - Medium
- Has been Observed L M H
- Rare Chances Risk Level

L - Low - First Aid Injury L - Low Severity
- Never Happened
Department: Access Scissor Production

R/ Hazard / Applicable Risk
Severity Probablility
S No. Activity / Sub Activity D/I/V N/A/E/L Explanati Risk Existing Control S/NS Proposed Control Opportunity Remarks
NR Concern Legal Req. Explanation H/M/L H/M/L Level
on
Revision History
S.No Revision No: Revision details Date
1 1 Severity explanations updated 30.01.2019
2 2 Fixture revised with secondary stopper protection - IMP Closed 01.02.2019
3 3 Pneuamtic tool provided - IMP Closed 05.09.2020
4 4 Detachable platform provided at station so that small height operator can easily perfrom the given task - IMP Closed 11.07.2021
5 5 Complete HIRA reviewed and occurrence revised for 3 significant hazards. 12.01.2022
6 6 Complete HIRA Revised - 4 significant hazards identified and 15 Improvement project identified and 6 are closed and 9 are open. 20.10.2022
Summary Condition For Significant(S):

1. Total nos. of Significant Risk 4 1.If the Risk Level number is more than 3
2. Total nos. of OCP 2 2.All Emergency and legal concerns
3. Total improvement projects undertaken 15 3.Flaura & Fauna
4. Top 3 Significant Risk Extension Platform Lifting
Pothole plate lifting
Offline ladder fitment and
dropping

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Format No.

M - Medium - Medical Aid Injury - May/ Can Happen L 1 2 3

- Rare Chances Risk Level

Tool may slip and injured to Hand & Leg May/Can

Tool may slip and injured to Hand & Leg May/Can

Hand/Finger May/Can Trained operator & OPL has been given to

Hand / finger May/Can

Summary Condition For Significant(S):

- May/ Can Happen L 1 2 3

- Rare Chances Risk Level

Department: Access Scissor Production

Summary Condition For Significant(S):

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