SLS/PROC/0001.1SMS This Baseline Risk Assessment · PDF fileAstral Risk Management was...

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1 SLS/PROC/0001.1SMS This Baseline Risk Assessment for Super Laboratory Services for 2010 is submitted in fulfilment of the Mine Health and Safety Act of 1996 on the identification of risks by the Owner of the Mine Conducted, facilitated and compiled by Astral Risk Management Consultants (NHD/ B Tech SM, M Tech RM, Masters Degree) In the Division of Issue based Risk Assessments for mining and other industries The next revision is required during January 2011

Transcript of SLS/PROC/0001.1SMS This Baseline Risk Assessment · PDF fileAstral Risk Management was...

Page 1: SLS/PROC/0001.1SMS This Baseline Risk Assessment · PDF fileAstral Risk Management was commissioned to facilitate the Baseline Risk Assessment for Super Laboratory Services on their

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SLS/PROC/0001.1SMS

This Baseline Risk Assessment for Super Laboratory Services for 2010 is submitted in

fulfilment of the Mine Health and Safety Act of 1996 on the identification of risks by the

Owner of the Mine

Conducted, facilitated and compiled by Astral Risk Management Consultants (NHD/ B Tech SM, M Tech RM, Masters Degree)

In the

Division of Issue based Risk Assessments for mining and other industries

The next revision is required during January 2011

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Declaration

Astral RM hereby declares that this study submitted for Super Laboratory Services, is an original work and has not been duplicated to or from any Baseline Risk Assessment, and that all the sources consulted or quoted are indicated and acknowledged by means of a

comprehensive list of references.

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Synopsis Astral Risk Management was commissioned to facilitate the Baseline Risk Assessment for Super Laboratory Services on their facility as well as services rendered to industries. This Baseline was conducted on the requirements of mining legislation in the republic of South Africa. International best practices were not excluded and incorporated where necessary to reduce risks during the implementation of recommendations made in this study. Super Laboratory Services has successfully obtained accreditation to render these specialised services and comply with relevant legislation. With the introduction of the Mine Health and Safety Act, 1996 (Hereafter the “MH&S Act”), mines have to assess where they are in terms of risk, identifying the major risks and thereby establishing their priorities and a system for future risk control. This baseline Risk Assessment need to be comprehensive and may lead to further, separate, more in-depth risk assessment studies. The Baseline Risk Assessment should be periodically reviewed (see page 1, bottom of page) to ensure that it is still relevant and accurate. Issue Based and Continuous Risk Assessments will need to be incorporated to address the identified major risk areas continuously. The Baseline Risk Assessment for Super Laboratory Services was conducted through site risk audits, workshops with management and employees as well as document assessment. Available historical data such as accidents and incident reports, inspections and audits done, as well as plans were studied to assess the risk record of Super Laboratory Services. Risk Audits Risk Audits were carried out by means of checklists on best practices in the mining industry. The Auditors used the following checklists: Facility and offices checklist; Calibration of equipment; Planned inspection checklist. Workshop A workshop was conducted with management and employees on 12 January 2010. Document assessment All available documents were studied and any unclear issues with regard to documents or plans discussed during the workshop session. Historical data All available historical data of Super Laboratory Services was researched and analysed. Note was taken of industry and international data for the Baseline Risk Assessment. Main Findings The findings indicate that the risks can be well managed within a proper Health and Safety Management system. Risks can be controlled to ensure a safe working environment for Super Laboratory Services employees. The risk levels of risks identified were very low. Certain areas of concern will be mentioned in the study and current controls evaluated.

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Main Recommendations Issue Based Risk Assessments As circumstances and needs arise, separate risk assessment studies need to be conducted. These will normally be associated with a system for the management of change. An additional risk assessment needs to be carried out when, for example:

• New equipment and machinery are introduced. • A system of work is changed or operations alter from the current. • After a serious accident or re-occurrence of similar types of incidents/ accidents

occur. • As new knowledge comes to light and information is received which may influence

the level of risk to Super Laboratory Services employees. Continuous Risk Assessments This is the most important form of risk assessment, which should take place continually, as an integral part of day-to-day management. It may not be as sophisticated as the hazard and risk assessment tools used for Baseline and Issue Based Risk Assessments, but in terms of ensuring safety and absence of health risks in the workplace, this form of risk assessment is the most powerful and important. Examples of Continuous Risk Assessment include: • Audits. • General hazard awareness linked to a campaign. • Pre-work assessments using checklists. (Planned Task Observations, Critical Parts and Task

Analyses, etc.). • Risk Assessments using a Risk Index/ Matrix method. Health and safety Management system To comply with the Mine Health and Safety Act requirements, a proper Health and Safety Management system as per OHSASH 18001 needs to be maintained. Acknowledgements The Management and Employees of Super Laboratory Services assisted with this study. Consultants who are competent in their field of expertise by way of knowledge, qualification, and experience in mining, metallurgy and engineering were used to assist in the assessment.

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Table of contents 1. Introduction 1.1 Competency of Assessors

1.2 Background of Super Laboratory Services

1.3 Legal requirements

1.4 Research problems

1.5 Reason for study

1.6 Research methodology and research design

1.7 Limitations of research 2. Review of data 2.1 Introduction 2.2 Historical data analysis

2.3 Identified problem areas for the physical conditions, processes, equipment, materials and the environment.

2.4 Behaviour based safety Analysis 2.5 Exposition of the problem 2.6 Competency requirements 2.7 Conclusion 3. Baseline Analysis 3.1 Occupational levels 3.2 Activity levels 3.3 Task levels 4. Strategy, levels of strategy and graphic representation of Baseline 4.1 Overall strategy 4.2 Operational strategy 4.3 Graphic representation of Baseline 5. Findings and recommendations 5.1 Findings

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5.2 Recommendations 5.3 Conclusion 6. Bibliography Appendix

A. Cover letter addressed to Super laboratory Services clients

B. Plans for Baseline area

C. Checklists for next revision

D. References

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1. Introduction 1.1 Competency of Assessors Astral Risk management was established in 1995. Astral is a risk management service company for national and international industries as well as the South African government. Astral Risk management is serving companies operating in the micro as well as the macro environment.

Astral is a service vehicle, which operates mainly by contracting-in expert consultants or companies, preferably, and by first choice, HDSA consultants or BEE compliant companies. This ensures the creation of a job market, which was never tapped into. Services, solutions and delivery capacity Astral’s key strength is the flexibility and depth of services and solutions. We analyse all complex risk control requirements and provide the answers. Through the application of tailored services and solution packages we consistently demonstrate our ability to beat our competitors when it comes to successfully completing complex risk management assignments. Astral offers solutions through multiple national and international methodologies and principles and ensures speedy results and solutions for risk management issues. We provide service capacity with regard to competent Safety and Risk management personnel available for the market. Astral is a dedicated alliance to company specific risk management needs through the capacity to deliver a professional and internationally acceptable solution to risk management problems. Risk assessments

We apply internationally accredited risk assessment tools to systems, products, manufacturing processes, equipment, plant and even less tangible subjects such as logistic or information flows. The risk assessment process is used to identify the possible ways in which failure could occur, the corresponding causes of failure, the corresponding effects of failure, and the impact on customer satisfaction as well as any implication of legal liability. 1.2 Background of Super Laboratory Services.

Their values Integrity Respect Responsibility and accountability Dedication Mission statement “To provide a trustworthy cost effective and safe analytical service to all our customers (big or small), this enables them to concentrate on their core business”

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Brief historical background Super Laboratory Services (Pty.) Ltd. (S.L.S.) was started in 1996, primarily to service Nigel Gold Mine, a small gold mine based at the old Springs Daggafontein property. The laboratory was situated in Nuffield on the old Raleigh Cycles premises. The initial owners were Nigel Gold Mines (which have since become Pamodzi Gold), Waste Products Utilisation (which have sold their shares back to S.L.S.) and K. B. (Ken) Gibbons. In 1998 S.L.S. opened a branch in Barberton on the Agnes Gold Mines premises. In 2002, S.L.S. opened a branch in Klerksdorp, an Afrikander Lease Gold Mines property (which has since become Uranium One – Rietkuil operations). S.L.S. is committed to their present operations, but also has plans to expand and diversify. Scope of operation of Super Laboratory Services (a) Chemical analysis of gold-bearing mineral ores, solutions, concentrates and bullion, by employing amongst other, the following techniques: i) fire assay analysis of gold and gravimetric finish; ii) AAS analysis of gold and base metals in solution; and (b) Metallurgical test work; (c) Carbon test work; (d) Grading analysis of crushed and milled ore samples; (e) Classical wet analysis, such as cyanide and lime titrations Sample Receiving (Bulks)

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Sample Receiving (Batching on LIMS

Drying Tables & Pulverising Room

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Sample Batching & Sample fluxing (Fluxing on LIMS)

Furnaces & Muffles

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Parting & Weighing (Weighing on LIMS

1.3 Legal requirements Compliance to the following legislation or best practice/ guideline is required:

•The SIMRAC guideline •The MHSA 1996 •International Risk Principles •ILO OHSAS 18002 •National Nuclear Act •SAQA Act •Hazards Substances Act •Workmen’s Compensation Act •COID Act •Atmospheric Pollution Prevention Act •Labour Relations Act •Employee Equity Act •Skills Development Act •Lead regulations 2001 •Environment conservation Act •OHS Act •BCE Act •Harmful Businesses Practice Act •Precious metals Act of 2005

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1.4 Research problems The levels of risk identified during this study are low and no significant risk exposure has been identified. However, the information gathered shows a quite clear picture of where the major risk areas lay and what precautions are being taken to mitigate the risks. 1.5 Reason for study

Astral was commissioned by Super Laboratory Services to conduct a baseline Risk Assessment of its facility and services. The baseline area is contained within the site only, and does not include any transport to and from the Laboratory, as this responsibility lies with the clients who deliver the material to the Laboratory.

1.6 Research methodology and research design

The risk assessment process (Extracted from the tripartite working group on risk assessment (25 March 1996, based on international risk principles, ref. DNV, Switzerland)

Baseline risk assessment With the introduction of the MH&S Act, mines have to assess where they are in terms of risk, identifying the major risks and thereby establishing their priorities and a system for future risk control. This responsibility includes services rendered by outside companies. Owners of mines are obliged to request a Baseline Risk Assessment from Manufacturers or Service Providers to ensure the product or service complies with Section 21 of the Mine Health and Safety Act of 1996. This Baseline Risk Assessment is comprehensive and may well lead to further, separate, more in-depth risk assessment studies. The Baseline Risk Assessment should be periodically reviewed to ensure that it is still relevant and accurate. Issue Based and Continuous Risk Assessments will need to be incorporated to achieve the “complete picture”. 1.7 Limitations of research

Limitations of the research include past and current assessment and needs to be revised annually as risks may change.

2. Review of data The review includes historical as well as current data obtained through audits, interviews and research. 2.1 Introduction Competent Consultants were used in collecting the data. Interviews with the current personnel took place on site or during the workshop. Historical data was obtained from Super Laboratory Services such as records, plans and on-site contractor procedures (SOP’s).

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2.2 Historical data analysis The following data was scrutinized and analysed to produce a clear picture of possible future repetitive problem areas, activities which have a high likelihood to result in a downgrading incident or accident, and tasks which could result in a behavioural error.

Inspection reports Task Analysis for similar activities Critical Task Analysis Accident/ Incident statistics Risk Audits Risk Assessments

2.3 Identified problem areas for the physical conditions, processes, equipment, materials and the environment. The following graphic representations show the potential risk variations of prominent health and safety issues within distinctive areas. No Functional

area Task

Risk level

Risk Controls

1 Sample receiving

Physical offloading of samples

Low Personal injury, Loss of samples

PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

2 Bulk sample preparation

Reduce size of rock Low FB in eye, personal injury

PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

3 Reduce the mass of crushed rock

Low FB in eye, personal injury

PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

4 Physical movement of prepared samples to the drying area

Low Slip & fall, falling objects

PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

5 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

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No Functional area

Task

Risk level

Risk Controls

6 Sample preparation

Placing the dish and sample into the drying facility

Low

Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

7 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

8 Crushing

Reduce size of rock Low FB in eye, personal injury

PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

9 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

10 Pulverising

Place new discs in Pulverisor if necessary

Low Hand injuries PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

11 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

12 Batching

Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

13 Fluxing

Physical inspection of crucibles

Low Hand injuries PPE, SOP Supervision Training Planned inspections

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No Functional area

Task

Risk level

Risk Controls

PTO’s Continuous risk assessments

14 Addition of flux mixture to crucibles

Low Dust and lead Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

15 Mixing of material in crucible

Low Dust and lead Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

16 Physical placement of tray at furnaces

Low Slipping and falling

Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

17 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

18 Furnaces

Preparation of furnace before loading

Low Respiratory problems and contamination

Dust extractor, PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

19 Placing of crucibles in furnace

Low Contamination, Burning

PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

20 Inspection of fusion process

Low Burning PPE, SOP Supervision Training Planned inspections

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No Functional area

Task

Risk level

Risk Controls

PTO’s Continuous risk assessments

21 Preparation of receiving moulds

Low Contamination, Burning, Falling objects

PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

22 Determine fusion is complete

Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

23 Pouring of the fused material

Low Contamination, Burning, Falling objects

PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

24 Transfer trolley to Cupellation

Low Contamination, Burning, Falling objects

PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

25 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

26 Muffle

Deslagging of lead button from mould

Low Hand injuries, FB, Burning

PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

27 Hammering of lead button

Low Hand injuries, FB, Burning

PPE, Gloves - heat resistant, SOP Supervision Training

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No Functional area

Task

Risk level

Risk Controls

Planned inspections PTO’s Continuous risk assessments

28 Placement of lead button onto Cupel

Low Heat/ Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

29 Inspection of Cupellation process

Low Heat/ Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

30 Removal of Cupel tray after determining processes complete

Low Heat/ Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

31 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

32 Parting

Addition of parting acid

Low Acid burn PPE, Gloves & overalls - acid resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

33 Drying of sample Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

34 Annealing of sample Low Burning PPE, Gloves - heat resistant, SOP Supervision

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No Functional area

Task

Risk level

Risk Controls

Training Planned inspections PTO’s Continuous risk assessments

35 Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

36 Weighing

Cleaning to prevent contamination

Low Dust PPE, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

No Processes,

Equipment, material Risk level

Risk Controls

1 Furnace Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

2 Muffle Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

3 Hotplates & water baths

Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

4 Drying tables Low Burning PPE, Gloves - heat resistant, SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

5 Crusher Low Personal injuries particularly hand injuries and FB in eye

PPE - Safety Glasses, Ear plugs, safety shoes, dust masks. Dust extraction system. SOP Supervision Training Planned inspections PTO’s

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No Processes, Equipment, material

Risk level

Risk Controls

Continuous risk assessments 6 Pulveriser Low Dust

inhalation & Personal injury

PPE – Dust masks, gloves when changing discs, Dust extraction system. SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

7 Swing mill Low Dust inhalation & Personal injury

Dust extraction system. SOP Supervision Training Planned inspections PTO’s Continuous risk assessments

No General

Risk Detail

1 Appointments MHS Act

Low Not required

2 Planned Inspections & Follow-up

Low Monthly

3 Planned Task Observations

Low Daily

4 Procedures and training thereof

Low Monthly

5 Safety meetings recorded

Low Minutes of meetings

6 Safety system OHSASH 18001

Low Implementing required elements for business

2.4 Behaviour based safety Analysis No Behaviour related

Risk Detail

1 Emergency Preparedness awareness

Low Emergency preparedness and response to incidents (proactive action). One minor accident recorded in existence of business

2 Corrective action on Planned Inspections

Low Follow up system on work done

3 Routine work "Auto Pilot"

Medium Supervision and motivation

4 Hazard awareness and compliance to planned objectives

Medium On the job training, Planned Task Observations

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2.5 Exposition of the problem

Super laboratory Services is responsible for the Laboratory and the activities on their premises only. Small amounts of sample material are handled, resulting in a low risk working environment. One minor cut of the finger accident is on record.

2.6 Competency requirements

2.6.1 Policy 2.6.1.1 Super Laboratory Services shall use personnel who are employed by, or under contract to the laboratory. 2.6.1.2 Laboratory management shall ensure the competence of all who operate specific equipment, perform tests, evaluate results and sign test reports. 2.6.1.3 Personnel performing specific tasks shall be qualified (considered to be competent) on the grounds of appropriate education, training, experience and/or demonstrated skills, as required (refer to the appendix to this section titled: “Requirements for competency”). 2.6.1.4 Where contracted and additional technical and key support personnel are used, the laboratory shall ensure that such personnel are supervised and competent and that they work in accordance with the management system related to quality of the laboratory. 2.6.2 Procedure Goals with respect to the education, training and skills of laboratory personnel: 2.6.2.1 Goals with respect to the education, training and skills of laboratory personnel shall be formulated and documented at biannual management reviews (refer to the appendix to this section titled: “Training goals for personnel”, for an example of such a record). 2.6.2.2 The training programme shall be relevant to the present and anticipated tasks of the laboratory. 2.6.2.3 The laboratory shall be responsible for fulfilling specified personnel certification requirements in instances where regulatory authorities, standards for the specific technical field or customers require personnel performing certain tasks to hold personnel certification. 2.6.3 Identification of training needs 2.6.3.1 Training, retraining and courses or sessions to develop and improve skills of personnel can be initiated at any time by the Laboratory Manager or Quality Manager in response to amongst other: a) decisions reached at management reviews; b) customer requests; c) corrective actions; and d) other strategic and operational issues. 2.6.4 Training and competency testing of personnel 2.6.4.1 Trainees shall be afforded access to relevant test methods, procedures and subject matter.

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2.6.4.2 The Laboratory Supervisor or qualified deputy shall explain the contents of applicable documentation to the trainee and impart as much related information as is necessary to ensure that the trainee has a thorough understanding of the documentation. 2.6.4.3 The trainer shall then demonstrate the test method or task and all associated procedures to the trainee, ensuring that the trainee is made aware of how information contained in the documentation is applied in practice and in accordance with the management system of the laboratory. 2.6.4.5 The trainee shall be allowed to familiarise him/her with both the theoretical and practical aspects of the test method or task and any ancillary procedures, while working under the supervision of a qualified person. 2.6.4.6 The period of familiarisation, further training and skills development shall be in accordance with the appendix to this section titled: “Requirements for competency”. 2.6.4.7 Upon completion of the familiarisation period, the trainee shall be required to undergo an examination on the theoretical and/or practical aspects of the test method or task. The examination shall be conducted by the Quality Manager in accordance with criteria set for each test method/task in the appendix to this section titled: “Requirements for competency”. 2.6.4.8 Assessment of the practical performance of the trainee shall be based on results obtained in a formal practical test or during method validation and/or proficiency tests. 2.6.4.9 The Quality Manager shall retain all marked answer papers in a training file, kept in his/her office. 2.6.4.10 The Quality Manager shall inform the trainee of the results of the examination and update the competency records (refer to the appendix to this section titled: “Record of competency”, for an example of such a record). 2.6.4.11 Unsuccessful candidates shall be treated in accordance with decisions reached between the Laboratory Manager and the Quality Manager. 2.6.4.12 Successful candidates shall be considered competent and authorised to conduct the test method or task. 2.6.5 Authorisation of personnel to perform certain tasks 2.6.5.1 Laboratory management shall authorise specific personnel to: a) perform particular types of sampling; b) perform particular types of testing; c) issue test reports (subject to SANAS authorisation); d) to give opinions and interpretations; e) to operate particular types of equipment. 2.6.5.2 Personnel responsible for the opinions and interpretation included in test reports shall, in addition to the appropriate qualifications, training, experience and satisfactory knowledge of the testing carried out, also have:

a) relevant knowledge of the technology used for the manufacturing of the items, materials, products, etc. tested, or the way they are used or intended to be used, and of the defects or degradations which may occur during or in service;

b) knowledge of the general requirements expressed in the legislation and standards; and;

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c) an understanding of the significance of deviations found with regard to the normal use of the items, materials, products, etc. concerned.

2.6.6 Maintenance of records of qualifications and training 2.6.6.1 The laboratory shall maintain records of the relevant educational and professional qualifications and experience of all technical personnel, including contracted personnel, in a training file, kept in the Quality Manager’s office. 2.6.6.2 The laboratory shall maintain records of the relevant training, authorisation(s), competence and skills of all technical personnel, including contracted personnel (refer to the appendix to this section titled: “Record of competency”). 2.6.6.3 Information regarding qualifications and training shall be readily available, and shall include the date on which authorisation and/or competence is confirmed. 2.6.6.4 Personnel shall be responsible for providing the Quality Manager with details of educational and professional qualifications and experience attained. 2.6.6.5 The Quality Manager shall be responsible for the maintenance of records of qualifications and training. 2.6.7 Effectiveness of training actions taken The effectiveness of the training actions taken shall be evaluated at biannual management reviews, taking into account amongst other:

a) marks obtained by trainees in theoretical exams and/or practical tests; and;

b) any increase in individual performance that can be attributed to training efforts.

2.6.8 Job descriptions The Laboratory Manager shall maintain current job descriptions for managerial, technical and key support personnel involved in testing, in which, as a minimum, the following shall be defined (refer to the section titled: “Organisation”): a) the responsibilities with respect to performing tests; b) the responsibilities with respect to the planning of tests and evaluation of

results; c) the responsibilities for reporting opinions and interpretations; d) the responsibilities with respect to method modification and development and validation of new methods; e) expertise and experience required; f) qualifications and training programmes; g) managerial duties.

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2.6.9 Related records

Identification Requirements for

competency to perform certain

tasks

Training goals for personnel Training record

Responsibility for collection, indexing and filing of records Quality Manager Quality Manager Quality Manager

Where kept Quality Manager’s office

Quality Manager’s office

Quality Manager’s office

Responsibility for maintenance of records Quality Manager Quality Manager Quality Manager

Access All staff All staff All staff

Responsibility for disposal of records Quality Manager Quality Manager Quality Manager

Retention time of records Indefinitely Indefinitely Indefinitely

2.7 Conclusion

Risk levels for Super Laboratory Services were rated low on the Risk matrix (See appendix page 43). Business continuity will not be affected as processes also fall within the low risk level.

3. Baseline Analysis The following occupation analysis demonstrates the risk levels as per the depicted Baseline area. Occupational levels At risk performance/ tasks No Occupation

Risk Detail

1 Director Low Monitor performance

2 Sample Receiver Low Detect substandard performance, correct & and monitor

3 Crusher Operator Low Prevent substandard performance at source

4 Section Leader Low Detect substandard performance, correct & and monitor

5 Lab. Operator

Low Detect substandard performance, correct & and monitor

6 Batcher Low Detect substandard performance, correct & and monitor

7 Fluxer Low Detect substandard performance, correct & and monitor

8 Furnace Operator Low Detect substandard performance, correct &

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No Occupation

Risk Detail

and monitor

9 Lab Analyst Low Low risk occupation

10 Data Capturer Low Low risk occupation

Activity levels No Grouped activities

Risk Detail

1 Offloading Low Detect substandard performance, correct & and monitor

2 Inspecting Low Monitor performance

3 Correlation Low Monitor performance

4 Crushing Low Detect substandard performance, correct & and monitor

5 Splitting/ Riffling Low Detect substandard performance, correct & and monitor

6 Transfer to next section Low Monitor performance

7 Transferring sample from received packet into sample dish

Low Monitor performance

8 Drying samples Low Detect substandard performance, correct & and monitor

9 Recording sample ID onto sample packet

Low Monitor performance

10 Pulverising Low Detect substandard performance, correct & and monitor

11 Sorting of samples Low Monitor performance

12 Preparation of batch Low Monitor performance

13 Transferring of the batch to fluxing

Low Monitor performance

14 Preparation of furnace tray Low Detect substandard performance, correct & and monitor

15 Weighing of samples Low Monitor performance

16 Loading/ unloading - Furnace Low Detect substandard performance, correct & and monitor

17 Muffling Low Monitor performance

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No Grouped activities

Risk Detail

18 Parting Low Monitor performance

19 Weighing Low Monitor performance

20 Reporting - Liaison with

customer Low Monitor performance

3.3 Task levels No Grouped tasks

Risk Detail

1 Physical offloading of samples

Low Detect substandard performance, correct & and monitor

2 Inspecting sample bags Low Monitor performance

3 Counting of samples Low Monitor performance

4 Checking paper work against the physical samples in presence of Customer

Low Monitor performance

5 Creating a worksheet on the LIMS system

Low Monitor performance

6 Record and rectify any discrepancies

Low Monitor performance

7 Reduce size of rock Low Detect substandard performance, correct & and monitor

8 Collecting of crushed rock Low Detect substandard performance, correct & and monitor

9 Reduce the mass of crushed rock

Low Detect substandard performance, correct & and monitor

10 Collecting of crushed rock

Low Detect substandard performance, correct & and monitor

11 Logging of sample ID's Low Monitor performance

12 Physical movement of prepared samples to the drying area

Low Detect substandard performance, correct & and monitor

13 Cleaning to prevent contamination

Low Detect substandard performance, correct & and monitor

14 Emptying of sample packet into sample dish

Low Detect substandard performance, correct & and monitor

15 Ensure ticket remains with sample

Low Monitor performance

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No Grouped tasks

Risk Detail

16 Placing the dish and sample into the drying facility

Low Detect substandard performance, correct & and monitor

17 Ensure the sample is fully dried

Low Detect substandard performance, correct & and monitor

18 Writing sample ID onto brown paper bag

Low Monitor performance

19 Collecting of crushed rock

Low Detect substandard performance, correct & and monitor

20 Placing sample into Pulveriser

Low Detect substandard performance, correct & and monitor

21 Collects pulverised material

Low Detect substandard performance, correct & and monitor

22 Check whether pulverised material is of the correct fineness

Low Detect substandard performance, correct & and monitor

23 Place new discs in Pulveriser if necessary

Low Detect substandard performance, correct & and monitor

24 Numerical sorting of packets Low Monitor performance

25 Physical inspection of sample ID's

Low Detect substandard performance, correct & and monitor

26 Placing the sorted packets into trays according to the worksheets created at sample receiving

Low Detect substandard performance, correct & and monitor

27 Physical placement of tray at fluxing

Low Detect substandard performance, correct & and monitor

28 Physical inspection of crucibles

Low Detect substandard performance, correct & and monitor

29 Correlation of tray against worksheet

Low Monitor performance

30 Addition of flux mixture to crucibles

Low Detect substandard performance, correct & and monitor

31 Transfer of sample aliquot to crucibles as per worksheet

Low Detect substandard performance, correct & and monitor

32 Capturing of sample on LIMS Low Monitor performance

33 Mixing of material in crucible

Low Detect substandard performance, correct & and monitor

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No Grouped tasks

Risk Detail

34 Addition of silver

Low Detect substandard performance, correct & and monitor

35 Coppering of tray for tray ID purposes

Low Detect substandard performance, correct & and monitor

36 Physical placement of tray at furnaces

Low Detect substandard performance, correct & and monitor

37 Completing worksheet Low Monitor performance

38 Determine fusion is complete

Low Detect substandard performance, correct & and monitor

39 Pouring of the fused material

Low Detect substandard performance, correct & and monitor

40 Recording of process Low Monitor performance

41 Transfer trolley to Cupellation

Low Detect substandard performance, correct & and monitor

42 Deslagging of lead button from mould

Low Detect substandard performance, correct & and monitor

43 Preparation of Cupels as per worksheet from furnace room

Low Detect substandard performance, correct & and monitor

44 Hammering of lead button

Low Detect substandard performance, correct & and monitor

45 Placement of lead button onto Cupel

Low Detect substandard performance, correct & and monitor

46 Inspection of Cupellation process

Low Detect substandard performance, correct & and monitor

47 Removal of Cupel tray after determining processes complete

Low Detect substandard performance, correct & and monitor

48 Correlation of worksheet against completed Cupel tray

Low Monitor performance

49 Transfer Cupel tray to parting area

Low Detect substandard performance, correct & and monitor

50 Correlation of worksheet against Cupel tray

Low Monitor performance

51 Preparation of parting tray

Low Detect substandard performance, correct & and monitor

52 Hammering of Prill Low Detect substandard performance, correct &

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No Grouped tasks

Risk Detail

and monitor

53 Transfer Prill to parting cups

Low Detect substandard performance, correct & and monitor

54 Addition of parting acid

Low Detect substandard performance, correct & and monitor

55 Addition of strong acid

Low Detect substandard performance, correct & and monitor

56 Washing of sample

Low Detect substandard performance, correct & and monitor

57 Drying of sample

Low Detect substandard performance, correct & and monitor

58 Annealing of sample

Low Detect substandard performance, correct & and monitor

59 Completion of worksheet

Low Detect substandard performance, correct & and monitor

60 Transfer of parting tray to weighing area

Low Detect substandard performance, correct & and monitor

61 Calibration of microbalance Low Monitor performance

62 Inspection of parting tray against worksheet

Low Monitor performance

63 Obtain the relevant microbalance worksheet from LIMS

Low Monitor performance

64 Transfer sample from cup to microbalance

Low Detect substandard performance, correct & and monitor

65 Record mass Low Monitor performance

66 Print microbalance worksheet

Low Monitor performance

67 Correlate microbalance worksheet to worksheet

Low Monitor performance

68 Attach microbalance worksheet to worksheet

Low Monitor performance

69 Transfer completed document to reporting office

Low Monitor performance

70 Preparation of report sheet Low Monitor performance 71 Correlation of microbalance

sheet, worksheet and request sheet

Low Monitor performance

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No Grouped tasks

Risk Detail

72 Protection of information Low Monitor performance 73 Filing of documents Low Monitor performance 74 Ensure customer receives

requested information timeously

Low Monitor performance

75 Ensure customer is satisfied with results

Low Monitor performance

76 Communication with customer

Low Monitor performance

77 Providing consultation to customer

Low Monitor performance

4. Strategy, levels of strategy and graphic representation of Baseline 4.1 Overall strategy To provide a trustworthy, safe and cost effective analytical service to all our customers (big or small) this enables them to concentrate on their core business. (See appendix – page 61) 4.2 Operational strategy 4.2.1 Safe operation of the following: (a) Chemical analysis of gold-bearing mineral ores, solutions, concentrates and bullion, by

employing amongst other, the following techniques: i) fire assay analysis of gold and gravimetric finish; ii) AAS analysis of gold and base metals in solution; and (b) Metallurgical test work; (c) Carbon test work; (d) Grading analysis of crushed and milled ore samples; (e) Classical wet analysis, such as cyanide and lime titrations 4.2.2 Proactive detection of substandard performances or conditions, correct immediately & and monitor. 4.2.3 Continuous health and safety training of employees (see 2.6.4) 4.3 Graphic representation of Baseline The risk values have been converted from the checklist criteria (see appendix page 41) to a more effective value display in the graphs. The risk profiles reflect the control effectiveness of current controls (residual risk) versus risk without controls (inherent risk). Assessment areas were combined to show a weighted average per item.

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0

50

100

150

200

250

Sam

ple

rece

ivin

g

Bulk

sam

ple

prep

.

Crus

hing

Batc

hing

Pulv

erisi

ng

Sam

ple

rece

ivin

g

Furn

aces

Flux

ing

Muf

fle

Part

ing

Wei

ghin

g

Repo

rtin

g

Functional Risk Profile

Inherent rating

Residual rating

1 to 100 = Low risk 300 to 1000 = Medium risk 900 to 10000 = High risk Inherent = risk levels without controls

0

50

100

150

200

250

Lab.

Ope

rato

r

Sect

ion

Lead

er

Crus

her O

pera

tor

Crus

her O

pera

tor

Batc

her

Sam

ple

Rece

iver

Furn

ace

Ope

rato

r

Flux

er

Lab

Anal

yst

Data

Cap

ture

r

Dire

ctor

Occupational Risk Profile

Inherent

Residual

1 to 100 = Low risk 300 to 1000 = Medium risk 900 to 10000 = High riskInherent = risk levels without controls Residual = risk levels with controls

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Total Task Risk Profile (including health and safety related tasks) 1-100= Low risk 300- 1000= Medium risk 900-10000= High risk Tasks Inherent Residual Emptying of sample packet into sample dish 90 90 Ensure ticket remains with sample 300 90 Checking paper work against the physical samples in presence of Customer 300 30 Cleaning to prevent contamination 100 30 Collecting of crushed rock 300 30 Collects pulverised material 300 30 Logging of sample ID's 100 30 Numerical sorting of packets 100 30 Physical movement of prepared samples to the drying area 100 30 Pouring of the fused material 300 30 Record and rectify any discrepancies 300 30 Reduce size of rock 300 30 Transfer of parting tray to weighing area 300 30 Creating a worksheet on the LIMS system 100 10 Inspecting sample bags 100 10 Physical placement of tray at fluxing 90 10 Placing sample into Pulveriser 90 10 Placing the dish and sample into the drying facility 30 10 Placing the sorted packets into trays according to the worksheets created at sample receiving 90 10 Record and rectify any discrepancies 100 10 Check whether pulverised material is of the correct fineness 100 9 Coppering of tray for tray ID purposes 30 9 Correlation of worksheet against completed Cupel tray 100 9 Determine fusion is complete 100 9 Ensure the sample is fully dried 30 9 Inspection of fusion process 100 9 Physical inspection of sample ID's 30 9 Physical inspection of tray against worksheet 100 9 Place new discs in Pulveriser if necessary 100 9 Placement of lead button onto Cupel 300 9 Placing of crucibles in furnace 100 9 Preparation of furnace before loading 100 9 Record mass 100 9 Recording of process 100 9 Reduce the mass of crushed rock 100 9 Removal of Cupel tray after determining processes complete 100 9

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Tasks Inherent Residual Transfer Prill to parting cups 100 9 Transfer sample from cup to microbalance 300 9 Addition of parting acid 30 3 Addition of silver 30 3 Addition of strong acid 30 3 Attach microbalance worksheet to worksheet 30 3 Capturing of sample on LIMS 30 3 Completing worksheet 30 3 Correlate microbalance worksheet to worksheet 100 3 Correlation of microbalance sheet, worksheet and request sheet 90 3 Counting of samples 300 3 Drying of sample 30 3 Ensure customer receives requested information timeously 30 3 Hammering of lead button 30 3 Hammering of Prill 30 3 Inspection of Cupellation process 30 3 Obtain the relevant microbalance worksheet from LIMS 100 3 Physical placement of tray at furnaces 30 3 Preparation of Cupels as per worksheet from furnace room 30 3 Preparation of parting tray 30 3 Preparation of report sheet 30 3 Print microbalance worksheet 100 3 Protection of information 100 3 Transfer completed document to reporting office 30 3 Transfer Cupel tray to parting area 100 3 Transfer trolley to Cupellation 30 3 Washing of sample 100 3 Writing sample ID onto brown paper bag 30 3 Annealing of sample 9 1 Communication with customer 9 1 Deslagging of lead button from mould 30 1 Ensure customer is satisfied with results 9 1 Filing of documents 9 1 Inspection of parting tray against worksheet 30 1 Mixing of material in crucible 9 1 Physical offloading of samples 9 1 Preparation of receiving moulds 9 1 Providing consultation to customer 9 1 Recording of fusion process 9 1

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Top 10 tasks Risk Profile

0

50

100

150

200

250

300

350

Empt

ying

of s

ampl

e pa

cket

into

sam

ple

dish

Ensu

re ti

cket

rem

ains

with

sam

ple

Chec

king

pap

er w

ork

agai

nst

the

phys

ical

sam

ples

in

pres

ence

of C

usto

mer

Clea

ning

to p

reve

nt co

ntam

inat

ion

Colle

ctin

g of c

rush

ed ro

ck

Colle

cts p

ulve

rised

mat

eria

l

Logg

ing

of sa

mpl

e ID

's

Num

eric

al so

rtin

g of

pac

kets

Phys

ical

mov

emen

t of p

repa

red

sam

ples

to th

e dr

ying

ar

ea

Pour

ing o

f the

fuse

d m

ater

ial

Top 10 Task Risk Profile

Inherent

Residual

1 to 100 = Low risk 300 to 1000 = Medium risk 900 to 10000 = High risk Inherent = risk levels without controls Residual = risk levels with controls

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5. Findings and recommendations 5.1. Findings

5.1.1. The risk levels at the laboratory are low and proper controls are in place 5.1.2. Legal requirements for this operation is monitored and inspected by the Labour Department Inspectorate who visits the site frequently. 5.2. Recommendations Continue with close supervision and on the job training. 5.3. Conclusions With the required resources available the strategy plan can be implemented successfully.

6. Bibliography Appendices to follow

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A. Cover letter addressed to Super laboratory Management

Super Laboratory Services The Director

Astral Risk Management P.O.Box 6599

Greenhills

Baseline Risk Assessment Super laboratory Services

Sir,

As requested, herewith the Baseline Risk Assessment for Super Laboratory Services.

The Baseline includes business as well as operational health and safety issues.

The Baseline will reflect the major risks for the Baseline area through graphical presentations of the levels of risks for functional areas, activities, occupations and tasks.

In addition, external historical data has also been analysed to identify any other possible failures. This includes investigation into previous significant incidents or accidents, current historical data of the working environment and failure of critical structures or machinery.

Implementation of the current strategy will ensure not only legal compliance but also ensures a more effective and proactive approach to maintain a safe working environment.

The utilisation of expert Consultants ensured that the data obtained has been correctly analysed and presented in an understandable manner.

Checklists have also been included for future use. DS Germishuizen CEO Astral Risk Management

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B. Plans for Baseline area

The plans for Super Laboratory Services.

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C. Criteria and Audit checklists C.1 Risk Criteria C.1.1 Impact criteria:

Criteria No Level of impact Risk value

Health & Safety Legal/ Governmental/ Regulatory Operational Community Environmental Security Procurement

1 Significant irreversible health & Safety effects to >50 persons; Significant prosecution and fines. Very serious litigation, including class actions.

100

2 Single fatality and/or severe irreversible disability (>30%) to one or more persons; Major breach of regulation. Major litigation.

30

3 Moderate irreversible disability or impairment (<30%) to one or more persons; Serious breach of regulation with investigation or report to authority with prosecution and/ or moderate fine possible

10

4 Objective but reversible disability requiring hospitalisation; Minor legal issues, non-compliances and breaches of regulation.

3

5 No medical treatment required – Incidental/ Near miss; Low-level legal issue.

1

C 1.2 Likelihood of occurrence

Likelihood

Category

Category Description Risk value

Almost certain The risk is almost certain to occur in the current circumstances

100

Likely More than an even chance of occurring 30

Possible Could occur quite often 10

Unlikely Small likelihood but could happen 3

Rare Not expected to happen – Event would be a surprise 1

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C.1.3 Inherent risk (Risk without controls)

The risk rating equals the impact multiplied with the Likelihood.

Category Category Description Risk rating from

checklists

Extreme This risk should be terminated / insured / controlled 10 000

High This risk should be insured / controlled 6000

Moderate This risk will typically be controlled (treated) 3000

Low Management will make an informed decision as to whether this risk must be controlled or absorbed by the business unit. The decision will be based on a “cost vs. benefit” approach

100

Insignificant Impact and probability is insignificant. This risk may be tolerated, and cost of losses will be absorbed by the business unit

1

C.1.4 Control effectiveness on residual risk (Risk with current controls)

Category Level Category Description Risk rating from

checklists

Extreme Immediate action

required

Management should take immediate action to reduce residual risk exposure to an acceptable level.

10 000

Very High Action required

Management should implement more controls or increase the effectiveness of current controls to reduce the residual risk to a more acceptable level.

6000

High Monitor Management should constantly monitor the risk exposure and related control effectiveness.

3000

Moderate Acceptable The residual risk exposure is acceptable to the mine.

100

Low Reduce control

Management may consider reducing the cost of control.

1

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Risk scoring chart or “Vulnerability Risk Assessment” – This scoring gives the following risk ranking assessed for each risk on consequence versus probability/ Likelihood: High risk – Score of 900-10000 Medium risk – Score of 300-1000 Low risk – Score of 1-100

Con

sequ

ence

/ Im

pact

C

onse

quen

ce/ I

mpa

ct

Catastrophic

100

Low

(100X1=100)

Medium

(100X3=300)

Medium

(100X10=1000)

High

(100X30=3000)

High

(100X100=10000)

Serious

30

Low

(30X1=30)

Low

(30X3=90)

Medium

(30X10=300)

High

(30X30=900)

High

(30X100=3000)

Moderate

10

Low

(10X1=10)

Low

(10X3=30)

Low

(10X10=100)

Medium

(10X30=300)

Medium

(10X100=1000)

Minor

3

Low

(3X1=3)

Low

(3X3=9)

Low

(3X10=30)

Low

(3X30=90)

Medium

(3X100=300)

Low

1

Low

(1X1=1)

Low

(1X3=3)

Low

(1X10=10)

Low

(1X30=30)

Low

(1X100=100)

1

3

10

30

100

Rare

Unlikely

Possible

Likely

Almost certain

Probability/ Likelihood

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C.1.5 Health and safety Worksheets Health and Safety

Sample receiving

Function Activity Occupation Task Inherent likelihoo

d Inherent

consequence Inherent

risk rating Residual likelihood

Residual consequence

Residual risk rating Risk Controls

Sample receiving Offloading Sample

Receiver

Physical offloading of

samples 3 3 9 1 1 1

Personal injury, Loss of samples

PPE, SOP

Visual inspection

Sample Receiver

Inspecting sample bags

10 10 100 3 10 30

Counting of samples

10 30 300 1 3 3

Correlation Sample Receiver

Checking paper work against the physical samples in presence of Customer

10 30 300 1 30 30

Creating a worksheet on

the LIMS system 10 10 100 1 10 10

Record and rectify any discrepancies

10 10 100 1 10 10

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Bulk sample preparation

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Bulk sample prep.

Crushing Crusher Operator

Reduce size of rock

30 10 300 3 10 30

FB in eye, personal injury

PPE, SOP

Collecting of crushed rock

10 30 300 3 10 30

Splitting/ Riffling

Crusher Operator

Reduce the mass of crushed

rock 10 10 100 3 3 9

FB in eye, personal injury

PPE, SOP

Collecting of crushed rock

10 30 300 3 10 30

Correlation Section Leader

Logging of sample ID's

10 10 100 3 10 30

Record and rectify any discrepancies

10 30 300 3 10 30

Transfer to next section

Crusher Operator

Physical movement of

prepared samples to the

drying area

10 10 100 3 10 30

Slip & fall, falling objects

PPE, SOP

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system, SOP

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Sample preparation

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Sample prep.

Transferring sample from received packet into sample dish

Lab. Operator

Emptying of sample packet into sample dish

3 30 90 3 30 90

Ensure ticket remains with sample

10 30 300 3 30 90

Drying samples

Lab. Operator

Placing the dish and sample into the drying facility

3 10 30 1 10 10

Burning

PPE, Gloves - heat resistant

Ensure the sample is fully dried

10 3 30 3 3 9

Recording sample ID onto sample packet

Lab. Operator

Writing sample ID onto brown paper bag

10 3 30 1 3 3

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system, SOP

Record and rectify any discrepancies

10 30 300 3 10 30

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Crushing

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Crushing Crushing Crusher Operator

Reduce size of rock

30 10 300 3 10 30

FB in eye, personal

injury

PPE, SOP

Collecting of crushed rock

10 30 300 3 10 30

Splitting/ Riffling Crusher Operator

Reduce the mass of

crushed rock 10 10 100 3 3 9

Collecting of crushed rock

10 30 300 3 10 30

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust

extraction system,

SOP

Record and rectify any discrepancies

10 30 300 3 10 30

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Pulverising

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Pulverising Pulverising Crusher Operator

Placing sample into Pulveriser

3 30 90 1 10 10

Collects

pulverised material

10 30 300 3 10 30

Check whether pulverised

material is of the correct fineness

10 10 100 3 3 9

Place new discs in Pulveriser if

necessary 10 10 100 3 3 9

Hand injuries SOP, PPE

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system,

SOP

Record and rectify any discrepancies

10 30 300 3 10 30

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Batching

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk rating Risk Controls

Batching Sorting of samples Batcher

Numerical sorting of packets

10 10 100 3 10 30

Physical inspection of sample ID's

10 3 30 3 3 9

Preparation of batch Batcher

Placing the sorted packets into trays according to the worksheets created at sample receiving

3 30 90 1 10 10

Record and rectify any discrepancies

10 30 300 3 10 30

Transferring

of the batch to fluxing

Batcher Physical placement of tray at fluxing

3 30 90 1 10 10

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system, SOP

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Fluxing

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Fluxing Preparation of furnace tray

Fluxer Physical inspection of crucibles

10 10 100 3 10 30

Hand injuries PPE, SOP

Correlation of tray against worksheet

3 30 90 1 10 10

Addition of flux mixture to crucibles

3 30 90 1 3 3

Dust and lead

Dust extractor, PPE, SOP

Weighing of samples Fluxer

Transfer of sample aliquot to crucibles as per worksheet

3 10 30 1 3 3

Capturing of sample on LIMS

3 10 30 1 3 3

Mixing of material in crucible

3 3 9 1 1 1

Dust and lead

Dust extractor, PPE, SOP

Addition of silver 3 10 30 1 3 3

Coppering of tray for tray ID purposes

3 10 30 3 3 9

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Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Transfer of furnace tray to Furnace Room

Fluxer Physical placement of tray at furnaces

3 10 30 1 3 3

Slipping and falling

PPE, SOP

Completing worksheet

10 3 30 3 1 3

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system, SOP

Record and rectify any discrepancies

10 30 300 3 10 30

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Furnaces

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Furnaces Loading Furnace Operator

Physical inspection of tray against worksheet

10 10 100 3 3 9

Preparation of furnace before loading

10 10 100 3 3 9

Respiratory problems and contamination

PPE, Dust extraction system, SOP

Placing of crucibles in furnace

10 10 100 3 3 9

Contamination, Burning PPE, SOP

Inspection of fusion process

10 10 100 3 3 9 Burning PPE, SOP

Recording of fusion process

3 3 9 1 1 1

Preparation of receiving moulds

3 3 9 1 1 1

Contamination, Burning, Falling objects

PPE, SOP

Unloading Furnace Operator

Determine fusion is complete

10 10 100 3 3 9

Burning PPE, SOP

Pouring of the fused material

10 30 300 3 10 30

Contamination, Burning, Falling objects

PPE, SOP

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Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Recording of process

10 10 100 3 3 9

Transfer trolley to Cupellation

3 10 30 1 3 3

Contamination, Burning, Falling objects

PPE, SOP

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system, SOP

Record and rectify any discrepancies

10 30 300 3 10 30

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Muffle

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Muffle Muffling Furnace Operator

Deslagging of lead button from mould

10 3 30 1 1 1

Hand injuries, FB, Burning PPE,SOP

Preparation of Cupels as per worksheet from furnace room

3 10 30 1 3 3

Hammering of lead button

10 3 30 3 1 3

Hand injuries, FB, Burning PPE,SOP

Placement of lead button onto Cupel

10 30 300 3 3 9

Heat/ Burning PPE, SOP

Inspection of Cupellation process

10 3 30 3 1 3

Heat/ Burning PPE, SOP

Removal of Cupel tray after determining processes complete

10 10 100 3 3 9

Heat/ Burning PPE, SOP

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Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Correlation of worksheet against completed Cupel tray

10 10 100 3 3 9

Transfer Cupel tray to parting area

10 10 100 1 3 3

Cleaning to

prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust

extraction system,

SOP

Record and rectify any discrepancies

10 30 300 3 10 30

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Parting

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Parting Parting Lab Analyst Correlation of worksheet against Cupel tray 10 10 100 3 3 9

Preparation of parting tray

10 3 30 3 1 3

Hammering of Prill 10 3 30 3 1 3

Transfer Prill to parting cups

10 10 100 3 3 9

Addition of parting acid 3 10 30 1 3 3 Acid burn PPE,SOP

Addition of strong acid 10 3 30 3 1 3

Washing of sample 10 10 100 3 1 3

Drying of sample 10 3 30 1 3 3 Burning PPE,SOP

Annealing of sample 3 3 9 1 1 1 Burning PPE,SOP

Completion of worksheet 10 3 30 3 1 3

Transfer of parting tray to weighing area

10 30 300 3 10 30

Cleaning to prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system, SOP

Record and rectify any discrepancies

10 30 300 3 10 30

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Weighing

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Weighing Weighing Lab Analyst Calibration of microbalance

10 10 100 1 3 3

Inspection of parting tray against worksheet

10 3 30 1 1 1

Obtain the relevant microbalance worksheet from LIMS

10 10 100 1 3 3

Transfer sample from cup to microbalance 10 30 300 3 3 9

Record mass 10 10 100 3 3 9

Print microbalance worksheet

10 10 100 1 3 3

Correlate microbalance worksheet to worksheet

10 10 100 1 3 3

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Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Record and rectify any discrepancies

10 30 300 3 10 30

Attach microbalance worksheet to worksheet

3 10 30 1 3 3

Transfer completed document to reporting office

3 10 30 1 3 3

Cleaning to prevent contamination

10 10 100 3 10 30

Dust

PPE, Dust extraction system, SOP

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Reporting

Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Reporting Data capturing Data Capturer Preparation of

report sheet 3 10 30 1 3 3

Correlation of microbalance sheet, worksheet and request sheet

3 30 90 1 3 3

Record and rectify any discrepancies

10 30 300 3 10 30

Protection of information

10 10 100 1 3 3

Filing of documents

3 3 9 1 1 1

Reporting Data Capturer

Ensure customer receives requested information timeously

3 10 30 1 3 3

Liaison

with customer

Data Capturer

Ensure customer is satisfied with results 3 3 9 1 1 1

Communication with customer

3 3 9 1 1 1

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Function Activity Occupation Task Inherent likelihood

Inherent consequence

Inherent risk

rating Residual likelihood

Residual consequence

Residual risk

rating Risk Controls

Director Providing consultation to customer

3 3 9 1 1 1

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Organisational strategy

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Appendices Baseline Risk Assessment attendance list

No. Initials &

Surname Occupation Qualification & experience

1

K.B Gibbons Director *National diploma in Analytical Chemistry. *Government Assayer Certificate of Competency. *Chemical Laboratory since 1982 to present.

2

B. Nyai Chemist *Trained at Mintek (in-house certificates) *Chemical and Metallurgical Laboratory since 1985 to present.

3

B. Kok Financial and HR Administrator

*B.Sc degree (1999 UNISA) *Final year B.Com Management Accounting student at UNISA *Chemical Laboratory since 1999 to present.

4

Health, Safety and Risk Consultants

Astral Risk management

46 years Mining, Safety, Risk management, BTech degree in Health and Safety Management, Masters degree in Risk Management

5

Super laboratory employees

As per occupation list

As per training section in document

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D. References

No. Reference 1 http://www.acts.co.za 2 Purdy, G. (1987). Systematic cause analysis technique: DNV, IRCA. 3 Haasbroek, D. (1998). Executive Safety/ Risk Management orientation: IRCA. 4 Rawson, C. (1988). Risk screening. Oracle Services [Article online]. Retrieved November

12, 2005 from the World Wide Web: http://www.oracle-services.com.au/risk_screening.htm.

5 5. "Process Hazard Analysis." Safety Management Services: Risk Matrix. 20 Nov. 2005,

http://www.sms-ink.com/services_pha_matrix.html. 6 Lihou, M (2002). Hazard and Operability studies 1. Lihou Technical & Software Services

[Article Online]. Retrieved November 10 2005 from the World Wide Web: http://www.lihoutech.com/hzp1frm.htm.

7 Lihou, M (2002). Hazard and Operability studies 2. Lihou Technical & Software Services

[Article Online]. Retrieved November 10 2005 from the World Wide Web: http://www.lihoutech.com/hzp2frm.htm.

8 Haasbroek, D. (1998). Principles of risk assessment: IRCA. Randfontein: James Park. 9 Management and Organisation Behaviour 5th edition By Laurie J. Mullins.

10 Risk Management and Risk Assessment by International Risk Control [IRCA]- Haasbroek, D.

11 Mining, Engineering and Risk Consultants contracted in.

12 Super Laboratory Services records and reports.

13 Current employees Super Laboratory Services