Risk assessment is the systematic process of identifying hazards, evaluating the likelihood and severity of harm, and implementing control measures to protect workers, students, and others in the production environment.
In VCAA PDT, risk assessment is required as a component of the scheduled production plan and must be applied throughout production.
Hazard: Anything with the potential to cause harm (e.g. sharp blade, toxic solvent, heavy timber off-cut)
Risk: The likelihood and severity of harm from a hazard in context (a sharp blade in a locked cabinet = low risk; a sharp blade being used by an untrained operator = high risk)
Control measure: Action taken to eliminate or reduce the risk
$$\text{Eliminate} > \text{Substitute} > \text{Engineer} > \text{Administer} > \text{PPE}$$
| Level | Example |
|---|---|
| Eliminate | Remove the hazardous chemical from the process entirely |
| Substitute | Replace solvent-based finish with water-based equivalent |
| Engineer | Install dust extraction on the router; add machine guard |
| Administer | Require tool induction; post safe operating procedures; limit access |
| PPE | Safety glasses, hearing protection, gloves, respirator |
Higher-level controls are always preferred. PPE is the last resort, not the first response.
Timber and wood products:
- Dust inhalation: use dust extraction; wear P2 respirator
- Splinters: handle with gloves; sand cut edges
- MDF/particleboard: formaldehyde off-gassing; ventilate; use low-emission products
Metals:
- Sharp edges and swarf: wear gloves; deburr all cut edges
- Metal dust inhalation: use extraction; wear respirator
- Hot metal: allow cooling time; use tongs or insulated gloves
Polymers:
- Fumes when cutting/laser processing: ventilate; use appropriate extraction
- Acrylic fragments: safety glasses essential
- ABS/styrene: toxic fumes when melted; avoid excessive heat
Chemicals and substances:
- Solvents (acetone, mineral turpentine): flammable; ventilate; store separately from ignition sources
- Adhesives: skin and respiratory sensitisers; wear gloves and work in ventilated areas
- Finishing products (paints, stains, lacquers): read SDS; follow stated PPE requirements
| Tool/Process | Key Hazard | Control |
|---|---|---|
| Drop saw/band saw | Kickback; blade contact | Guard in place; clamp work; induction before use |
| Router (hand/table) | Flying debris; vibration | Eye protection; hearing protection; correct RPM |
| Drill press | Spinning workpiece if not clamped | Clamp all work; correct feed rate |
| Laser cutter | Fume and particulate; UV/laser eye injury | Full enclosure; extraction on; never bypass interlocks |
| 3D printer (FDM) | Fumes from heated polymer; hot end contact | Ventilate; do not touch nozzle during/after operation |
| Soldering/welding | Fumes; UV radiation; burns | Extraction; face shield; fire-rated clothing |
For each significant process, document:
1. Hazard identified
2. Risk rating (High/Medium/Low) based on likelihood × severity
3. Control measure(s) applied
4. Residual risk after controls
5. Responsible person
KEY TAKEAWAY: Risk assessment is a legal and ethical obligation in production. It must be proactive (before work begins) and updated when new hazards are identified during production.
EXAM TIP: Use the hierarchy of controls when suggesting risk management measures. ‘Wear goggles’ (PPE) is correct but lower-order. ‘Install a machine guard and wear goggles’ demonstrates understanding of the hierarchy.
