This example risk assessment has been prepared using the
F-HS20 General Risk Assessment form template - a purpose-built template designed to focus entirely on what matters: identifying hazards, rating risk and recording controls, without any unnecessary fields getting in the way.
The file is supplied in fully editable MS Word format and can be easily customised and saved to Google Docs format if required. The document uses pre-defined style formatting throughout with styles to match the risk-ratings which are input using select boxes pre-populated with all possible risk ratings. All text is in Calibri font for improved readability.
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- Form number and title
- Information-classification
- Version
- Page number / total pages
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Manufacturing Operations Risk Assessment
This fully completed manufacturing operations risk assessment example has been prepared by a qualified health and safety professional. It covers a typical range of hazards, risks and associated control measures for manufacturing activities including machinery use, material handling, surface treatment and assembly operations and can be used as a starting point when developing your own risk assessment documentation.
What Does This Manufacturing Operations Risk Assessment Cover?
This risk assessment identifies the key hazards associated with manufacturing operations including;
- Machinery entanglement and contact — contact with unguarded moving parts including rotating components, drive belts, shafts and cutting tools
- Manual handling — lifting and positioning of components, raw materials, finished goods and tooling
- Noise — prolonged exposure to high noise levels from manufacturing machinery, pneumatic tools and press operations
- Hazardous substances — skin contact with or inhalation of cutting fluids, lubricants, solvents, adhesives and surface treatment chemicals
- Slips, trips and falls — oil, coolant, swarf and debris on the manufacturing floor causing slips and trips
Each hazard includes an inherent risk rating ranging from Moderate to Substantial, and a comprehensive listing of applicable control measures covering areas such as;
- Machine guarding, lock-off/tag-out procedures and authorised operator controls
- Mechanical aids, manual handling training and ergonomic work layout
- Noise assessments, acoustic engineering controls and hearing protection zones
- COSHH assessments, local exhaust ventilation and chemical-resistant Personal Protective Equipment (PPE)
- Floor cleanliness, prompt spillage clean-up, anti-slip footwear and marked walkways
A residual risk rating is then assigned to each hazard, demonstrating how effective risk management reduces overall risk to a tolerable level.
A Professional, Easy-to-Use Risk Assessment Template
This document uses colour-coded header styles matched to risk ratings, making it quick to read and easy to communicate during toolbox talks and worker training. A built-in risk rating matrix supports consistent evaluation of likelihood and consequence, and hazard pictograms using internationally recognised ISO warning symbols are included alongside relevant hazard entries — improving clarity and helping to highlight risks and mandatory controls.
The result is a completed risk assessment that looks professional, reads clearly, and demonstrates a structured and effective approach to risk management.
Who Is This Risk Assessment Template Suitable For?
This manufacturing operations risk assessment template is suitable for health and safety advisers, health and safety managers, production supervisors, maintenance staff and any employer with a duty to assess risks associated with manufacturing activities. It can be implemented as a standalone document or as part of a broader occupational health and safety management system aligned with ISO 45001.
Note: This example risk assessment is supplied for use as guidance only and should be reviewed and completed by a competent person.