Risk assessment and controls
Risk assessment and controls examines the process of identifying hazards, evaluating risk and selecting proportionate controls. NGC expects the five-step model, the hierarchy of control, and the meaning of suitable and sufficient.
Core rules
- Hazard = potential to cause harm; risk = likelihood and severity of harm.
- Suitable and sufficient assessment identifies hazards, decides who may be harmed and how, evaluates risks, records significant findings, and sets a review date.
- Apply the hierarchy in order: eliminate, substitute, engineering controls, administrative controls, PPE. PPE is last because it protects only the wearer and depends on correct use.
- Controls must reduce risk so far as is reasonably practicable (SFAIRP); residual risk remains and must be recorded and monitored.
- Vulnerable groups (young workers, new/expectant mothers, disabled workers, lone workers) need specific consideration.
Worked example
A distribution centre manually lifts 25 kg boxes from pallet to conveyor. The assessment records the load, frequency, twist and route. Elimination is not feasible, so the team introduces adjustable conveyors and vacuum lifts (engineering), reduces box weight to 15 kg by supplier change (substitution/design), trains staff in technique and organises rotation (administrative), and issues gloves only as a final supplement. Reasoning: the hierarchy targets the source of risk, not just behaviour, and the residual risk is lower and monitored through incident reports.
Traps
Do not start with PPE or manual handling training as the main control. Do not produce a generic assessment without significant findings. Do not ignore residual risk or review. Do not confuse a risk rating with a control. Do not treat SFAIRP as do nothing or do everything.