Manufacturing Risk Assessment
Generate HSE-compliant manufacturing risk assessments in 60 seconds
14,000
Annual injuries in manufacturing
15
Fatal injuries per year
Contact with machinery
Leading cause of injury
Low
Assessment difficulty
Common Manufacturing Hazards
Key risks identified by the HSE for manufacturing work
Moving parts, entanglement, crushing, cutting from production equipment
Control Measures:
- Machine guarding on all dangerous parts
- Two-hand controls or light curtains
- Lock-out tag-out (LOTO) for maintenance
- Regular maintenance and inspection
Chemicals, solvents, dusts, fumes from manufacturing processes
Control Measures:
- COSHH assessments for all substances
- Local exhaust ventilation (LEV)
- PPE including RPE where required
- Safe storage and handling procedures
Lifting raw materials, finished products, repetitive tasks
Control Measures:
- Mechanical aids (conveyors, hoists, forklifts)
- Ergonomic workstation design
- Job rotation to reduce repetition
- Training on safe lifting techniques
High noise levels from machinery causing hearing damage
Control Measures:
- Noise surveys to identify problem areas
- Engineering controls (enclosures, dampening)
- Hearing protection zones
- Audiometric testing for exposed workers
Spills, debris, uneven surfaces in production areas
Control Measures:
- Good housekeeping procedures
- Anti-slip flooring in wet areas
- Clear walkways and storage areas
- Prompt clean-up of spills
Forklifts, trucks, and other vehicles in production areas
Control Measures:
- Separate pedestrian and vehicle routes
- Speed limits and signage
- Reversing alarms and mirrors
- Trained and authorized drivers only
Relevant Legislation
Laws and regulations that apply to manufacturing risk assessments
Health and Safety at Work etc. Act 1974
Primary legislation for workplace health and safety
Provision and Use of Work Equipment Regulations 1998 (PUWER)
Requirements for safe work equipment including machinery
Control of Substances Hazardous to Health Regulations 2002 (COSHH)
Requirements for handling hazardous substances
Control of Noise at Work Regulations 2005
Requirements for managing workplace noise exposure
Sample Tasks We Cover
Generate risk assessments for these common manufacturing activities
Frequently Asked Questions
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About Manufacturing Risk Assessments
A manufacturing risk assessment is a systematic process of identifying hazards, evaluating risks, and implementing control measures for manufacturing work activities. Under UK health and safety law, employers and self-employed workers must assess risks to health and safety arising from their work.
The HSE 5-step approach involves: (1) identifying hazards, (2) deciding who might be harmed and how, (3) evaluating risks and deciding on precautions, (4) recording findings, and (5) reviewing and updating as necessary. Our AI-powered generator follows this methodology to create professional, compliant assessments.
Whether you're a sole trader, small business, or larger contractor, documented risk assessments protect both workers and businesses. They demonstrate compliance with health and safety law and provide evidence of due diligence in case of incidents.