Risk Assessment within Production Operations

Risk Assessment within Production Operations

Date/Time: Date(s) - 14/09/2022 - 16/09/2022( 8:00 am - 5:00 pm )
Location: Malaysia, Kuala Lumpur


A risk assessment is a systematic process that involves identifying, analyzing, and controlling hazards and risks. It is performed by a competent person to determine which measures are, or should be, in place to eliminate or control the risk in the workplace in any potential situation. Risk assessment is one of the major components of a risk analysis. Risk analysis is a process with multiple steps that intends to identify and analyze all of the potential risks and issues that are detrimental to the business. This is an ongoing process that gets updated when necessary. These concepts are interconnected and can be used individually. This training on risk assessment explores the difference between risk and risk assessment and explains the types and strategies of risk assessment. Furthermore, demonstrate the applications and plans.


  • Recognize the difference between hazard, risk and risk assessment
  • Learn how to evaluate different types of risk
  • Develop the skills of applying advanced risk assessment techniques relevant to the process industry
  • Develop a strategy for planning and implementing risk reduction action plans
  • Appreciate the contribution of human error to accidents

Who Should Attend?

  • Supervisors and line management who need to fulfill their role within HSE-MS
  • Production, project, process, mechanical, control, maintenance and HSE personnel
  • Personnel involved in implementing the Company’s HSE Management System


Introduction to Risk Assessment

  • Course introduction: delegate and tutor introductions; course objectives
  • The concepts of hazards, risk and risk assessment and a review of the risk assessment process
  • Syndicate Exercise: Risk Assessment and HSMS to control risk
  • Personal Safety and Process Safety
  • Syndicate exercise: Process Safety exercise (Part 1)
  • Risk Assessment tool: BowTie Diagram
  • Syndicate exercise: Process Safety exercise (Part 2)
  • Layers of Protection and Barriers (Control Measures)

Elements of HSE Management Systems and Process Safety

  • A brief Introduction to Environmental Issues
    • Key Environmental Issues
    • Land, Air and Water
  • Process Safety – Fires and Explosions
    • Fault Tree Analysis
    • Dangerous Substances and Explosive Atmospheres Risk Assessment
  • Key elements of the HSE Management System
  • Elements of HSE – Management Systems
    • Selection of Contractors
    • Control of Contractors
    • Case Study: Contractors doing their thing
    • Check and Audit of Contractors
  • Isolation of Plant
  • Case Study: Fire in a Polypropylene Plant
  • Process Safety – Understanding the process and the effect of change
  • Syndicate exercise: Cooling system failure

Major Accidents and How they occur

  • Permit to Work Systems
    • Principles of operation
    • Example of failure
  • System Failure: Review of a Process Over-Ride Incident
  • How “Barriers” are defeated – How major incidents occur
    • Major Accidents and how they happened – The timeline to disaster
    • Major Accidents and how they happened – An out of hours’ plant explosion
    • Consideration of Root Cause
  • Process Safety: Leading and Lagging Indicators
  • Major Incident Analysis
    • Incident Occurrences; Eye Witness Testimonies; Analysis Team
    • Gathering Evidence; Expert Support; Incident Sequence
    • Preliminary Causes; Root Cause Analysis; Human Factors
  • Risk Control Recommendations; Analysis Report

Human Factors and Risk Assessment

  • Layers of Protection
    • Review of BowTie
    • LOPA
  • Hierarchical task analysis ‘HTA’
  • Introduction to human factors and human error
    • Errors and Violations
    • Syndicate Exercises
  • Review of a Major Industrial Incident involving errors and violations
  • Improving human reliability
  • Reactive and Active Monitoring

Major Incidents, Emergency Response, and the role of Safety Culture

  • Rules versus Risk Assessment
  • Process safety: the start-up phenomena
  • Case Study: Everything went wrong
  • Rethink – what was “the” root cause?
  • What is Health and Safety Culture?
  • Development of positive safety culture and how to promote safety culture
  • Overview of Emergency Response Planning
  • Review of Barriers

Training Methodology

  • Case Studies.
  • Individual and group discussions and exercises.
  • Intensive training by using templates, diagrams, and charts.
  • Planning activities and presentations.
  • Self-assessments.
  • Action plan.

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