NEBOSH

MANAGEMENT OF HEALTH AND SAFETY

UNIT IG1:
For: NEBOSH International General Certificate in Occupational Health and Safety

Task 1: Auditing approach

Question 1 (a)

1. Prior Accident: A significant accident six months prior led to the decision to undertake a
health and safety audit instead of an inspection. This demonstrates the need for a
thorough evaluation of the safety management system rather than a cursory inspection.

2. Comprehensive Assessment: An audit evaluates an organization's health and safety

rules and procedures, which helped identify systemic flaws at Northern Mill.

3. External Expertise: Hiring an external health and safety consultant indicates a need for
impartiality and in-depth understanding in identifying and addressing minor issues.

4. Change Implementation: Following the major accident, there was a clear aim to reform
and improve current safety measures. This would be better addressed through an audit
that evaluates the effectiveness of policies and implementation.

5. Employee Safety Knowledge: The owner discovered major gaps in factory workers'
health and safety knowledge, prompting an audit to evaluate training efficacy.

6. Regulatory Compliance: Audits verify compliance with health and safety laws,
especially in high-risk factory settings.

7. Preventive Approach: The audit aimed to create a structured preventative maintenance

program for machines, going beyond routine checks and prioritizing proactive risk
management.

8. Policy and Procedure Update: The audit aimed to examine and update health and
safety policies and risk assessments to ensure they are thorough and current.

9. Continuous Improvement: The audit aims to create a baseline for Northern Mill's
health and safety practices, promoting a culture of continuous improvement.

10. Stakeholder Assurance: Conducting an audit demonstrates to stakeholders, including

employees and customers, that the organization is dedicated to ensuring a safe working
environment.

11. Risk Identification and Mitigation: Audits help identify, analyses, and mitigate risks in
complex environments like textile factories.
 12. Feedback Mechanism: The audit encourages feedback from all levels of the company,
including workers and supervisors, ensuring effective health and safety management.

Question 1 (b)

• Increased Credibility: Using an outside auditor gives the audit findings at Northern Mill more
legitimacy, which is important, particularly in light of the tragic accident. This outside
Validation shows stakeholders—such as staff members and clients—that the business is
committed to resolving its health and safety problems.

• Specialization and Expertise: The external auditor provided specialized health and safety
knowledge that might not have been available within. This is especially crucial because Northern
Mill uses intricate textile manufacturing methods that call for specific expertise to guarantee that
safety regulations are fulfilled.

• Objective Assessment: An external auditor offers an objective viewpoint that is essential for
precisely determining safety flaws and areas in need of improvement. By maintaining
objectivity, internal biases and conflicts of interest are less likely to affect the audit's conclusions.

• Regulation Compliance: External auditors usually have a thorough understanding of the most
recent rules and procedures for compliance. By their engagement, Northern Mill's operations are
guaranteed to comply with legal requirements, possibly averting fines or other legal issues.

• Identification of New hazards: An external auditor is better positioned to discover hidden or

new hazards that internal staff members could miss because of the prior accident and the
complexity of the textile production process.

• Focus on Core Operations: Northern Mill was able to keep its attention on its primary
operational tasks by contracting out the audit process. This strategy guarantees a complete and
efficient safety audit is carried out with the least amount of disturbance to regular business
operations.

Task 2: Management of risks

Question 2

1. Health and Safety Policy Revision: As a proactive measure to manage risks and make sure
policies are current, Northern Mill revised their health and safety policy in response to the tragic
accident and pertinent.
2. Risk Assessments Update: In order to identify and mitigate specific dangers related to textile
manufacturing, the company updated the risk assessments for actions carried out on the factory
floor.

3. Preventative Maintenance Program: Ensuring that all machinery has a planned preventative
maintenance program in place helps reduce the risk of accidents resulting from equipment failure
and keeps the machinery safe and functional.

4. Annual Refresher Training: Mandating that all employees in factories finish Annual
refresher training guarantees that all staff members are up to date on the most recent safety
protocols.

5. Improvement of Induction Training: Northern Mill revamped its induction program to

incorporate fundamental health and safety instruction, guaranteeing that newly hired staff
members are aware of the hazards and safety protocols right away.

6. Consultation with Workers: To aid with the customization of training and policies to the real
needs and gaps in worker understanding, the owner spent time evaluating the knowledge of
factory workers about health and safety.

7. Hiring a Full-Time Health and Safety Advisor: Hiring a full-time health and safety advisor
guarantees continuing focus on safety matters, acting as a point of contact for any safety-related
questions, and continuous risk management.

8. Clearly Labeled Machinery: Every machine has a label that includes its name, load capacity,
and basic operating instructions. This label helps to prevent misuse and alerts workers to
important operational limitations.

9. Environmental Condition Monitoring: It's a good idea to keep a close eye on the humidity
and temperature in the drying chambers to help prevent equipment malfunctions and guarantee a
secure working environment.

10. Factory Floor Access Control: Installing "no unauthorized access" signs on doors helps
restrict access to places that may be unsafe and lowers the possibility of mishaps involving
untrained or unauthorized workers.

11. Reaction to Near Misses: In the event of a near miss, prompt action and the stopping of
equipment show a robust on-the-ground safety protocol to avert additional mishaps.
12. Near Miss inquiry: A comprehensive inquiry was launched after the near miss, which is
essential to figuring out what went wrong and averting similar situations in the future.

13. Emergency Preparedness: The fact that the machinery has an emergency stop button and
that Supervisor S acted quickly after the near-miss incident demonstrate that emergency
procedures are available and in place.

14. Communication Tools: The capacity to swiftly monitor risks and react to emergencies is
improved by the use of two-way radios for instantaneous communication throughout the
manufacturing floor.

Task 3: Individual factors

Question 3

1. Lack of Experience: The new manufacturing worker's assignment to run a machine they had
never used before suggested that they were inexperienced with the equipment. This inexperience
using the particular device may have contributed to their failure to identify the associated risks.

2. Insufficient Training: Based on the circumstances, it's possible that the new manufacturing
worker wasn't given enough instruction on how to operate the particular equipment before being
assigned to it. The disaster was probably caused in part by inadequate instruction on how to load
and operate the dyeing vessel safely.

3. Inadequate Induction: Despite the fact that the induction procedure was revised to
incorporate a basic health and safety training, Supervisor R's delivery was hostile and might have
been lacking, which might have left the new employee with insufficient knowledge on the safety
procedures.

4. Pressure to Perform: Due to a delivery date inaccuracy, Supervisor R specifically put

pressure on the new employee to expedite the process, which increased the risk of rushing and
omitting safety precautions in order to meet deadlines.

5. Fear of Authority: The new employee may have been afraid that Supervisor R would report
them if they disobeyed, which made them continue without asking for more advice or support in
spite of their worries.
6. Absence of Supervision: The worker was left unsupervised at the crucial point and told that
the next supervisor was "probably around somewhere," which may have given them the
impression that they had to handle things on their own.

7. Stress and Anxiety: The employee's judgment and decision-making skills may have been
hampered by the pressure of feeling hurried and intimidated by Supervisor R.
8. Inadequate Risk Assessment: It's possible that the new manufacturing worker was not properly
trained to evaluate the hazards of overloading the machine, which is a crucial step in running the
machinery safely.

9. Lack of acquaintance with emergency procedures: It is unclear from the scenario whether
the new employee was conversant with emergency stop protocols or what to do when a machine
sounds a warning, which is essential in averting mishaps.

10. Communication problems: The worker's comprehension of the instructions or safety

procedures may have been further hampered by any language or communication problems.

11. Confidence to Challenge Unsafe Orders: One possible factor in the situation's escalation
was the new employee's lack of confidence or belief that they had the right to question
Supervisor R's unsafe command.

12. Awareness of Safety Signs: It's unclear whether the employee received sufficient training on
how to identify and handle safety alerts on machinery, such as the overload warning that flashed
on the device.

13. Physical Readiness: Reaching into the machine suggests a lack of knowledge of the
mechanical risks, perhaps as a result of not being physically ready or conscious of the risks
associated with dealing with moving parts.

Because of the strain and surroundings they were placed in, in addition to inadequate training
and assistance, these variables put the new factory worker at a higher risk of experiencing a near
miss.

Task 4: Management of near miss

Question 4

1. Prompt Action: In order to avoid a possible harm, Supervisor S took immediate action
when she saw the new factory worker reaching into the dyeing tank.
2. Emergency Stop Activation: Supervisor S quickly depressed the machine's emergency
stop button, exhibiting a suitable reaction to the circumstance and adherence to
emergency protocols.
3. Immediate Shutdown of Machine: Ordering the machine to be shut down immediately
was a decisive move that stopped the potentially dangerous equipment from being used
going forward and reduced the possibility of more mishaps.
4. Personalized Attention to the Employee: Supervisor S showed concern for the
employee's mental as well as physical health by bringing the upset worker aside to a
peaceful room.
 5. First Aid Response: In her capacity as the shift's first responder, Supervisor S examined
the worker's wrist to make sure no physical harm had gone unnoticed.
6. Effective Use of Communication Tools: Using the two-way radio to ask the owner to
keep an eye on the factory floor showed how to manage the situation and guarantee
ongoing supervision.
7. Instant Reporting to Management: Supervisor S made sure that upper management
was aware of the near miss and could take the appropriate action by notifying the owner
of the situation right away.
8. Managing the Emotional Impact: By allowing the recently hired manufacturing
worker to return home to recuperate, you're demonstrating that you recognize the
psychological toll that these kinds of accidents may have and that mental health is just as
important as physical safety.
9. Near Miss Investigation: With the owner's assistance, a systematic strategy to
comprehending and recording what transpired was highlighted, indicating the importance
of this step in averting future incidents.

Overall, Supervisor S demonstrated effective crisis management skills that not only addressed
the immediate safety concerns but also the longer-term implications of the incident on the
worker’s well-being.

Task 5: Procedural controls

Question 5

1. Machine Labeling: Workers were given vital operational information by having each
machine, including the dyeing machine, prominently labelled with its name, load capacity
limit, and basic operating instructions.
2. Health and Safety Policy: Northern Mill's upgraded health and safety policy contained
protocols and recommendations meant to guarantee safe operations throughout the
manufacturing floor.
3. Risk Assessments: Updated risk assessments for factory floor jobs assisted in
pinpointing particular hazards connected to every piece of equipment, including the dying
machines.
4. Preventative Maintenance Program: By keeping all equipment, including the dyeing
machines, in good operating order, the program's planned preventative maintenance
helped lower the likelihood of mechanical breakdowns.
5. Training Programs: To keep factory workers aware about operational and safety
protocols related to their activities, especially those involving the dying machines, all
workers are required to undergo an annual refresher course.
6. Induction Training: To acquaint new hires with machinery such as the dyeing
machines, induction training comprised fundamental health and safety information as
well as a factory floor overview.
 7. Supervisory Oversight: The risk connected with machine operations was managed in
part by the presence of supervisors like Supervisor S, who are informed about the
machinery and safety procedures.
8. Emergency Procedures: In the event of an emergency, emergency stop buttons on
various machinery, such as the dyeing machine, offered a prompt way to halt operations.
9. Access Control: The factory's restricted access points, marked with signs that said "no
unauthorized access," helped make sure that only authorized and trained workers could
access the dying machines.
10. Clear contact: In the event of an emergency, the factory floor could respond and
coordinate quickly thanks to the adoption of two-way radios, which allowed for
instantaneous contact.
11. Employee Empowerment: Employees were urged to speak out about harmful situations
and take part in safety talks, which may have included problems with the dyeing
equipment.

All of these procedural controls worked together to reduce the risks that come with running the
dyeing machines at Northern Mill, but how well they are implemented and followed by staff
members will determine how effective they are.

Task 6: Policy implementation

Question 6

Based on the scenario provided, here are the points detailing how Northern Mill has
implemented the revised health and safety policy over the past six months:

1. Preventing Accidents and Near Misses: The organization has made a number of efforts,
most notably via updating processes and equipment, to reduce accidents and near misses.
2. Looking into Accidents and Near Misses: After the near miss, an investigation was
launched right away, demonstrating a dedication to comprehending and averting similar
incidents in the future.
3. Creating Safe and Healthy Working Environments: Efforts to update policies and
provide staff training point to a shift in the direction of safer and healthier working
environments.
4. Ensuring Safe Plant and Equipment: This policy component is supported by the
establishment of a scheduled preventative maintenance program for all machinery, which
guarantees that the equipment is kept in safe operating condition.
5. Establishing and assessing Health and Safety targets: It appears from the owner's
proactive approach—which includes hiring a full-time health and safety adviser—that
Northern Mill maintains a continuous process for establishing and assessing safety
targets.
6. Determining Health and Safety Risks and Hazards: The organization's dedication to
identifying potential risks and hazards is shown in the revised risk assessments for
industrial tasks.
7. Providing enough Training: A commitment to providing enough training is
demonstrated by the mandate that all manufacturing workers complete an annual
 refresher course and the revamping of the induction training to incorporate health and
safety components.
8. Providing Health and Safety Information to Workers: This policy feature is supported
by the handout of printed copies of the health and safety policy to newly hired
employees, notwithstanding Supervisor R's resentment towards it.
9. Involving Workers: The owner has demonstrated a commitment to involving workers
in safety management by holding discussions with factory workers to evaluate their
awareness of and participation in safety procedures.
10. Provision of Resources: Employing a full-time health and safety advisor and improving
equipment upkeep and safety training show that the necessary resources are available to
ensure the policy's effectiveness.
11. Communication and Enforcement of Safety measures: Policy implementation is
demonstrated by the use of clear labeling on machinery and the enforcement of safety
measures by supervisors such as Supervisor S.
12. Emergency Preparedness: Signs of preparation and safety provisions include
emergency stop buttons and prompt action in case of an emergency.
13. Monitoring and Control: Consistent observation of local environmental factors, such as
humidity and temperature, guarantees that safety regulations are followed.
14. Access Control: By limiting who has access to the factory floor, only trained and
authorized individuals may operate the machinery, which lowers the possibility of
unintentional injury.

These bullet points highlight Northern Mill's concerted efforts to put its updated health and
safety policy into effect, demonstrating a thorough and proactive strategy to improve worker
safety over the previous half-year.

Task 7: Workers’ duties in the workplace

Question 7

The following points illustrate potential areas in which employees may not have completely
collaborated with their employer in carrying out the duties under ILO Recommendation No. 164,
based on the situation given for Northern Mill:

1. The Attitude of Supervisor R: Supervisor R has spoken loudly their opinion that the
modifications to health and safety management are a waste of time andmoney, which
indicates a lack of cooperation with the employer’s efforts to enhance safety.
2. Resentful Induction Training: Supervisor R conducted the induction in a resentful
manner, providing only printed copies of the health and safety policy. This suggests that
crucial safety information was not provided adequately and that there was insufficient
cooperation to guarantee that new hires received the necessary training.
3. Encouraging Risky Behavior: In defiance of the employer's safety standards and as a
sign of a lack of cooperation in preserving a safe working environment, Supervisor R gave
new manufacturing worker instructions to rush a task and priorities speed above safety.
 4. Absence of Supervision: Neglecting to follow safety procedures meant to guarantee the
safety of new employees is reflected in leaving them unsupervised with machinery they
are not familiar with.
5. Threatening Behavior: By threatening to report the new employee for disobeying
dangerous orders, Supervisor R has shown disrespect for cooperative safety procedures
and fostered a hostile work environment that may deter safe work practices.
6. Disregarding Safety Warnings: Supervisor R had already departed when the new factory
worker turned on the dyeing machine and it signalled an overload, demonstrating a lack of
collaboration in ensuring that activities were conducted safely and in accordance with
protocol.
7. Inadequate Communication: Supervisor R's failure to cooperate in guaranteeing
ongoing safety oversight is further demonstrated by his lack of communication regarding
the whereabouts of Supervisor S, the next supervisor, and appropriate handover
procedures.
8. Failure to Follow disaster Protocols: The new employee's initial response to the
machine alert before Supervisor S stepped in suggests that not all employees may be
completely assisting in disaster preparedness.
9. Opposition to Policy Changes: A general lack of collaboration among certain employees
with the new safety policies and procedures may point to a larger problem that could
jeopardize factory safety efforts.
10. Poor Participation in Safety Programs: If other employees have the same views as
Supervisor R on the importance of safety training, this may result in low participation in
safety programs, which are essential for the efficient application of safety measures.
11. Failure to follow safe work practices: The scenario suggests that there could not be
enough collaboration to continuously follow safe work practices, especially when it comes
to obeying load capacities and machinery operating procedures.
12. Reluctance to Report Safety Issues: Some employees may have a culture of not
reporting near-misses or safety issues, which is impacted by supervisors' attitudes. This
makes it more difficult for the employer to properly address and resolve these issues.

In order to maintain a safe and healthy workplace, these points emphasize the necessity
of ongoing efforts to promote collaboration and compliance with safety standards and
policies among all workers at Northern Mill.

Task 8: Benefits of worker involvement

Question 8

As indicated by the following scenario features, involving Northern Mill's industrial workers in
workplace health and safety can result in considerable benefits:

1. Increased Safety Awareness: Including employees in safety talks and training could help
them better grasp safety procedures, which will improve their awareness of and ability to
implement safety precautions.
2. Improved Compliance with Safety Protocols: Employees who are engaged in the creation
and execution of safety protocols are more likely to adhere to these measures since they are
aware of their significance and goal.
3. Greater Safety Ownership: Employees who actively participate in health and safety
frequently grow to feel a sense of responsibility for the workplace, which inspires them to uphold
and encourage safety regulations.
4. Improved Risk Identification: Factory floor employees are familiar with the workings and
possible dangers firsthand. Their participation may result in more precise risk identification and
useful mitigation recommendations.
5. Quicker Identification and Response to Safety Issues: Employees engaged in safety
procedures are more likely to spot and address safety issues promptly, averting mishaps and near
misses.
6. Empowerment via Knowledge: Employees who receive safety training and participation are
better equipped to perform their jobs in a safe and efficient manner, which enhances workplace
safety as a whole.
7. Cultural Shift towards Safety: Employee involvement can assist in bringing about a change
in the factory culture that places a higher priority on safety and encourages everyone to take an
active role in making the workplace safer.
8. Innovations for Safety Improvement: Employees engaged in safety may offer creative
suggestions for enhancing safety based on their regular interactions with the equipment and
procedures.
9. Improvement of Teamwork and Morale: When employees perceive that their opinions are
appreciated and that their health comes first, collaborative safety initiatives can boost morale and
teamwork among them.
10. Reduction in Accidents and Injuries: The number of accidents and injuries can be greatly
reduced with improved adherence to safety procedures and heightened awareness of potential
hazards.
11. Enhanced Productivity: A safer workplace lowers lost time from injuries and accidents,
resulting in more reliable output and efficiency.

These possible advantages emphasize how crucial it is for employees to actively participate in
Northern Mill's safety procedures, especially in light of the organization's recent safety initiatives
and difficulties.

Task 9: Learning lessons from adverse events

Question 9

Learning lessons from adverse events such as the near miss at Northern Mill is crucial for
multiple reasons, all aimed at improving workplace safety and operational efficiency:

1. Preventing Recurrence: By addressing the causes of near misses, learning from them helps
to ensure that similar instances don't happen again.
2. Strengthening Safety Standards: Every occurrence offers opportunities to reinforce safety
processes by revealing important details about potential flaws in them.
3. Improving Worker Safety: By identifying and resolving the issues that contributed to the
near-miss, a safer workplace is created and workers are shielded from potential harm.
4. Regulation Compliance: Drawing lessons from events can assist guarantee adherence to
health and safety laws, which can avert negative legal and financial repercussions.
5. Cutting Costs: Medical bills, equipment damage, and lost productivity are just a few of the
direct and indirect costs that accidents frequently result in. Taking all we can from them to cut
costs in the future
6. Boosting Employee Confidence: When employees see that their employer takes occurrences
seriously and works to prevent them, they are more likely to feel valued and safe.
7. Creating a Safety Culture: All staff members are encouraged to participate in safety
activities when there is a commitment to learning from unfavorable situations.
8. Preserving Reputation: By responsibly handling and growing from safety accidents, as well
as by demonstrating a commitment to safety, the organization can preserve or improve its
reputation.
9. Improving Training Programs: Training programs can be made more relevant and
successful at preventing similar mishaps by utilizing the insights from incidents.
10. Encouraging Continuous Improvement: A continuous improvement strategy for
workplace safety includes routinely reviewing events and near misses.
11. Employee Empowerment: Giving workers a voice in the analysis and creation of safety
incident remedies gives them a sense of empowerment and may result in safer solutions that
work better.
12. Encouraging Effective Risk Management: Knowledge of incidents facilitates the
improvement of risk assessment and management plans, bringing them closer to the real
obstacles that arise in the workplace.

For Northern Mill, addressing and learning from the recent near miss not only mitigates
immediate safety risks but also contributes to long-term operational stability and workforce well-
being.