Risk Assessment: Cosmetics Manufacturing Process

September 3, 2022 7 min read business cosmetic-industry industry accidental-chemical-splash-spillage and-cooling-systems bags barrels breakers carton-box-papers carton-boxes casks chemical-resistant-gloves circuit-breaker cosmetic-flow-production-process cosmetics-manufacturing-process distribution-panels drums efficient-lighting elcb-earth-leakage-circuit-breaker electrical-forklift emergency-lights fire-alarm-system fire-evacuation firefighting-equipment forklift forklift-re-charger fuses-and-circuit-breakers gfci-ground-fault-circuit-interrupter hand-held-pallet-jack-and-forklift-truck hazards health-safety heating housekeeping ibc-totes jerricans junction-boxes loading-unloading-the-raw-materials-to-from-storage-rack mcb-miniature-circuit-breaker medium-size-vessels occupational-safety packaging-materials plastic-wipes product-safety raw-material-warehouse receiving risk-assessment safety-analysis smoke-heat-detector switches toolbox-talk-safety-forum transportation waste-reduction
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Risk Assessment: Cosmetics Manufacturing Process

  1. Understand the process flow on how to manufacture the product

  2. Identify the hazards from its process step (task)

  3. Decide who might be harmed and how

  4. Evaluate the risks and decide on precaution

  5. Record your findings and implement them

  6. Review your assessment and update if necessary

Cosmetic Flow Production Process Flow

Cosmetic Flow Production Process Flow

Cosmetic Production Process Flow Common EHS Hazards

Receiving raw material from W/H

Receiving raw material from W/H

1.1 Common EHS Hazards
Exposure to dangerous works affecting the occupational health & safety of employees (HS002) Fall from elevated platform / high-level racks when material lifting / manual handling of raw materials during receiving process

Unsafe use of material handling equipment, e.g. drum-handling truck, forklift trucks / hand-held pallet jack for stock movement of various sizes/package types of receiving raw materials Improper handling, stacking & storage of receiving raw materials Ergonomics hazards Slip, trip & falls

1.1 Recommendation
Proper use of the on-site personal protective equipment and safe working methods for working at height, receiving dock safety, forklift safety, manual lifting & material handling, safe racking, stacking & storage of receiving raw materials in the warehouse (e.g., bags, jerricans, barrels, drums, casks, IBC totes, medium-size vessels) and prevention of slips, trips & falls (HS002-CM001)

1.2 Common EHS Hazards
Unsafe working conditions of electrical plugs, extension cords, and faulty electrical wiring cause immediate fire hazards, electrical hazards from electrical shock, and electrocution (HS006).

1.2 Recommendation
Proper insulation of electrical plugs, cords, and wiring (HS006-CM001). Ground Fault Circuit Interrupter (GFCI) protection and weatherproof enclosure are required for all outlets in wet and damp locations(HS006-CM002). Earth Continuity Connector (ECC) connection for powered hand tools and machinery - e.g., electrical forklift, forklift re-charger etc (HS006-CM003).

1.3 Common EHS Hazards
Exposed, impaired, and frayed electrical wiring causing an immediate fire hazard, electrical hazards from electrical shock, and electrocution (HS007)

1.3 Recommendation
All electrical wiring is in good condition and all fuses and circuit breakers are of the correct rating (HS007-CM001).

1.4 Common EHS Hazards
Overloaded electrical circuits and damaged switches/electrical panels causing immediate fire hazards, electrical hazards from electrical shock, and electrocution (HS008)

**1.4 Recommendation
**All electrical panels/systems are operated within the legal electrical capacity loading limit. (HS008-CM001)
All distribution panels, breakers, switches, and junction boxes are completely enclosed and protected from dust, vermin, and wet conditions(HS008-CM002). Circuit protection devices should not be bypassed to effectively limit or stop the flow of
current, fuses, circuit breakers (e.g., MCCB - Molded Case Circuit Breaker, MCB - Miniature Circuit Breaker, ELCB - Earth Leakage Circuit Breaker, GFCI - Ground Fault Circuit Interrupter) are common devices to detect a fault condition that could represent a potential electrical shock hazard due to short circuit or overloading (HS008-CM003).

1.5 Common EHS Hazards
Overload outlets and branch circuits due to misused extension cords and multiple power strips causing immediate fire hazards, electrical hazards from electrical shock, and electrocution (HS009)

1.5 Recommendation
Extension cords should never be left coiled up to damage insulation due to inductive heating (HS009-CM001).

1.6 Common EHS Hazards
Ineffective & inadequate means of fire detection (HS012)

1.6 Recommendation
Installation of effective and adequate fire detection system/devices – e.g., fire alarm system, smoke/heat detector (HS012-CM001).

1.7 Common EHS Hazards
Inadequate warning signage and floor marking for fire evacuation (HS013)

1.7 Recommendation
Adequate posting of warning signage and floor marking for fire evacuation at receiving raw material warehouse area (HS013-CM001).

1.8 Common EHS Hazards
Obstructed / unsafe means of escape (HS014)

1.8 Recommendation
All escape routes (i.e., stairways, aisles & main access/egress from receiving raw material warehouse) are easily identifiable, free from obstructions and clearly illuminated during normal or emergency situations(HS014-CM001).

1.9 Common EHS Hazards
Unsafe/excessive storage of flammable/combustible receiving raw materials causing immediate fire hazard – Raw materials receiving inventory with flammable/combustible cosmetic chemical solvents/ reagents contents(HS015)

1.9 Recommendation
No excessive build-up of stock to create unsafe conditions – Good logistics management for optimized warehouse stock control (HS015-CM001).

1.10 Common EHS Hazards
Signs of people smoking near an area of flammable, combustible, and explosive materials(HS016)

1.10 Recommendation
Enforcement of the No smoking policy throughout the warehouse areas except in safe and designated areas far away from the location (HS016-CM001).

1.11 Common EHS Hazards
Inadequate and/or malfunctioning firefighting equipment (HS017)

1.11 Recommendation
Provision and maintenance of adequate firefighting equipment for sustainable compliance (HS017-CM001).

1.12 Common EHS Hazards
Inadequate and/or malfunctioning emergency exits including emergency lights that are part of the emergency exit installation (HS018)

1.12 Recommendation
Adequate installation and maintenance of sufficient emergency exits in pair with emergency lights for sustainable compliance (HS018-CM001).

1.13 Common EHS Hazards
Inadequate automatic fire suppression system in high-risk areas – receiving raw materials with cosmetic flammable/combustible chemical solvents /reagents contents(HS019)

1.13 Recommendation
Adequate installation and maintenance of automatic fire suppression systems (e.g., automatic sprinkler system) to keep in serviceable condition (HS019-CM001).

1.14 Common EHS Hazards
Blocked/locked emergency exits(HS021)

1.14 Recommendation
Unblock / unlock emergency exits from the receiving raw material warehouse area leading to the designated safe place during fire evacuation (HS021-CM001).

1.15 Common EHS Hazards
Handling & storage of Dangerous / Hazardous cosmetic chemical solvents/reagents for receiving skin and respiratory contacts of hazardous chemical solvents/reagents when accidental splash and spillage from receiving process, handling & storage (HS023)

1.15 Recommendation
Conduct a workplace chemical survey in the receiving raw material warehouse area to identify hazardous areas or work tasks (e.g., receiving, transportation, loading/unloading the raw materials to/from storage rack) giving rise to the most exposure; and to assess the need for and the effectiveness of exposure control measures in receiving raw material warehouse areas (HS023-CM001).

1.16 Common EHS Hazards
Reduce worker exposure to chemicals - source control of chemical exposure (HS023-CM002).

1.16 Recommendation
Training and communication to inform workers about the hazards of chemicals they are handling for receiving & storage, e.g., MSDS, SOP for bulk storage safety & emergency response plan on how to handle raw material leakage during receiving, toolbox talk & safety forum, etc. (HS023-CM003).

1.17 Common EHS Hazards
Provision and use of proper PPE but do not just depend on safety glasses, face masks or protective chemical-resistant gloves in case of accidental chemical splash & spillage reduce hazardous chemical exposure first (HS023-CM007).

1.17 Recommendation
Poor ergonomics of working conditions and equipment (HS024) Ergonomically designed equipment, machines, and work station for receiving raw material warehouse operation - Provision of hand-held pallet jack and forklift truck for receiving raw material transfer and storage (HS024-CM001).

1.18 Common EHS Hazards
Proper manual handling / correct lifting techniques (HS024-CM004).

1.18 Recommendation
Automation / Semi-automation for those hands-on, labor-intensive warehouse activities (HS024-CM005).

1.19 Common EHS Hazards
Poor housekeeping conditions/ practices create an unsafe workplace (HS025)

1.19 Recommendation
Sustainable Workplace Cleanliness – Non-slip work area floor and receiving raw material warehouse storage are cleared of the access paths(HS025-CM001).

1.20 Common EHS Hazards
Removal of unused materials from bulk storage areas (HS025-CM003).

1.20 Recommendation
Regular workplace inspection for sustainable housekeeping (HS025-CM004).

1.21 Common EHS Hazards
Proper chemical stacking / de-stacking, segregation of bulk stock, safe stock movement to prevent overhead, and falling hazards and store materials against walls or partitions only in an amount that will not endanger the stability of the wall or partition, and automated storage in receiving raw material warehouse areas (HS025-CM005).

1.21 Recommendation
Proper postage of hazard warning signage and floor marking and floor marking at receiving raw material warehouse area - divert people traffic from the warehouse areas by clearly marked paths (HS025-CM006).

1.22 Common EHS Hazards
Inadequate consumption review of key raw materials and waste generation from receiving raw material warehouse operation (EN001)

1.22 Recommendation
Better procurement control of ordering and properly storing the right types and quantities of raw materials (e.g., carton boxes, plastic wipes, etc.) for receiving (EN001-CM001).

1.23 Common EHS Hazards
Reduction program initiatives of resource consumption and waste reduction (EN001-CM002).

1.23 Recommendation
Proper disposal practices of waste materials to reduce environmental impacts (EN001- CM003).

1.24 Common EHS Hazards
Usage of renewable resources for receiving raw material warehouse operation (EN001- CM004).

1.24 Recommendation
Reusing and recycling non-hazardous materials – carton box papers, plastic wipes, packaging materials, etc. (EN001-CM005).

1.25 Common EHS Hazards
No proper measurement, monitoring, and tracking control of energy consumption from factory facilities, processes, and systems (EN004)

1.25 Recommendation
Engagement initiative of LF Energy and Waste Efficiency Project (EN004-CM001).

1.26 Common EHS Hazards
Process changes and behavioral practices to reduce energy consumption and use less carbon-intensive sources - e.g. turning off lights in unused receiving warehouse areas (EN004-CM002).

1.26 Recommendation
Installation of technologies or equipment to reduce energy use - e.g. efficient lighting, heating, and cooling systems, and more energy-efficient powered material lifting equipment (EN004-CM003).

This handbook is applicable for the Supplier Factory’s Intermediate Practitioner for EHS improvement and follow-up, including risk evaluation, assessment and governance in place for the identified hazards & control measures. It is expected the Supplier factory should have fundamental risk assessment knowledge before engagement so. This is to be continue…