Workshop Risk Assessment After a Near Miss

Main hazards

1. Overlocker entanglement: loose sleeves, hair or jewellery can be pulled into the moving parts; the near miss shows this is not hypothetical. Severity: cuts, finger injury or worse; likelihood: high with 24 students and loose clothing. Priority: high.
2. Heat press burns and fire: the press is unattended, at 90 cm (near hand/arm height), with no guard or warning. Severity: serious burns or fire; likelihood: medium to high. Priority: high.
3. Sublimation ink fumes: strong smell indicates poor ventilation; repeated exposure can cause respiratory irritation. Severity: medium; likelihood: high while the press is in use. Priority: medium-high.
4. Iron burns and cable trips: irons are hot and may be left face-down; cables cross walkways. Severity: medium; likelihood: medium. Priority: medium.
5. Rotary cutter cuts: blades are sharp and can run into fingers if used without a ruler or glove. Severity: medium; likelihood: medium. Priority: medium.
6. Eyewash provision: only one station for 24 students; if a chemical or ink splashes an eye, access may be delayed. Severity: high; likelihood: low. Priority: medium.

Justification Priority is not simply the worst possible outcome; it combines severity with how likely the hazard is in this room. The overlocker and heat press come first because both have already produced a near miss or unsafe condition, and both can cause serious injury within seconds. Fumes rank next because the smell shows exposure is occurring now. Rotary cutters and irons matter but are more controllable with direct supervision.

Hierarchy of control The hierarchy runs: eliminate the hazard, substitute something safer, use engineering controls, then administrative controls, then PPE. PPE is the last line of defence, not the first.

Overlocker

• Elimination/substitution: where possible, pre-finish seams by another method, or restrict overlocker use to supervised small groups. This removes exposure for most students.
• Engineering: ensure the machine has a finger guard and a presser-foot guard; check that the emergency stop or foot-pedal control works; use a foot pedal rather than a hand switch so hands stay away from the needle.
• Administrative: tie back hair, remove lanyards and loose sleeves, and require students to tuck in clothing. Set a rule that fingers stay at least 5 cm from the needle. Train students on the specific machine and supervise closely.
• PPE: not a substitute for guarding; close-fitting apron or sleeves may help but can also catch, so clothing control is better.

Heat press

• Elimination/substitution: use a cold-peel or lower-temperature transfer process if it achieves the required result; otherwise restrict pressing to the teacher.
• Engineering: install local exhaust ventilation at the press; fit a guard or interlock so the press cannot close while hands are in the platens; mount at a safe working height (the current 90 cm is too low for safe leverage and hand clearance).
• Administrative: write a risk assessment, display operating instructions, require the press never to be left unattended, and allow cooling before changing transfers. Keep a fire extinguisher nearby.
• PPE: heat-resistant gloves for handling hot platens or transfers, and eye protection if there is a splash risk.

Why both engineering and administrative controls Engineering controls reduce the chance of injury regardless of student behaviour, but they do not remove the need for training, supervision and rules. Administrative controls alone rely on people remembering to behave safely, which is unrealistic with 24 students. Together they provide layers of protection.

Safe operating procedure: heat press

1. Before use: check the risk assessment is in place, the press is on a stable surface at a safe height, the cable is undamaged, and local exhaust ventilation is running. Set the temperature and time according to the transfer manufacturer’s instructions.
2. During use: keep hands and fingers clear of the platens; use the handle, not the hot plate. Never leave the press unattended while it is hot or while a transfer is loaded. Do not wear loose sleeves, lanyards or dangling jewellery. Keep flammable materials away.
3. After use: switch off and allow to cool before cleaning or storing. Remove the transfer with tongs or heat-resistant gloves. Report any burn, smoke or unusual smell immediately.
4. Emergency: for a burn, cool under running water for at least 10 minutes and seek first aid; for a fire, raise the alarm, switch off power if safe, and use the correct extinguisher; for eye exposure, use the eyewash station and seek medical help.

Managing the remaining lesson time The teacher should stop the production run and use the remaining time for a safety reset. With 50 minutes, a realistic plan is:

• 5 minutes: stop all machines, account for students and check for injuries.
• 10 minutes: brief the class on the two incidents and the new rules: no loose sleeves at the overlocker, no unattended heat press.
• 10 minutes: rearrange the room - clear walkways, move the heat press to a safer height if possible, open windows and use fans only as a temporary measure, not as a substitute for ventilation.
• 15 minutes: supervised practice on the sewing machines only, with the overlockers and heat press out of use until the risk assessment is updated.
• 10 minutes: record the incidents and inform the head of department or health-and-safety lead.

The teacher should not try to complete the original production target. The near miss and the unattended press show that the current controls are inadequate; finishing the tote bags is less important than preventing a serious injury.