Risk assessment is the identification and evaluation of hazards. Risk management is the ongoing process of implementing, monitoring, and reviewing controls throughout production.
In Unit 4, VCAA emphasises that risk management is applied during production — not just planned in advance. Students must demonstrate active, responsive management of safety throughout the making process.
1. Identify hazards
- Review all materials, tools, processes, and workspace conditions before and during production
- Update hazard identification when changes occur (new material introduced, different tool used, workspace condition changes)
2. Assess risk
- Evaluate each hazard for likelihood (how often might it occur?) and severity (how bad could the harm be?)
- Combine to give a risk rating (Low/Medium/High or numerical matrix)
3. Implement controls
- Apply the highest appropriate level of control from the hierarchy (Eliminate → Substitute → Engineer → Administer → PPE)
- Document controls in the production plan
4. Monitor and review
- During production: check that controls are working; observe actual conditions
- If a control is not effective, escalate to a higher-order control
- After an incident or near-miss: review and revise the risk management plan
Production plans change. Risk management must respond:
| Change | Risk Management Response |
|---|---|
| Switch to different adhesive | Review SDS for new product; update PPE requirements |
| Machine breaks; switch to hand tool | Assess new hazards from hand tool use |
| New chemical substance introduced | Source SDS; train users; update storage procedures |
| Working in a different workspace | Re-assess workspace hazards; check extraction is available |
Safety Data Sheet (SDS) / Material Safety Data Sheet (MSDS):
- Legally required document for all hazardous chemicals
- Contains: composition, hazards, first aid measures, handling and storage, disposal, PPE requirements
- Must be available in the workspace wherever the chemical is used
- SDS must be consulted before using any unfamiliar chemical
HAZCHEM classification: Chemical hazards are classified under the GHS (Globally Harmonised System) with standardised pictograms:
- Skull and crossbones: acute toxicity
- Flame: flammable
- Corrosion: corrosive materials
- Health hazard: sensitiser, carcinogen, reproductive hazard
Storage requirements:
- Flammables stored in dedicated flammable storage cabinet, away from ignition sources
- Oxidisers stored separately from flammables
- Corrosives in secondary containment to prevent spills contaminating other substances
PPE requirements must be matched to the specific hazard:
| Hazard | PPE |
|---|---|
| Flying particles, dust | Safety glasses (minimum); face shield for high-risk operations |
| Noise above 85 dB | Earmuffs or earplugs |
| Chemical splashes | Chemical-resistant gloves; safety glasses/face shield |
| Inhalable fumes/dust | P2 particulate respirator; chemical cartridge respirator for organic vapours |
| Sharp materials | Cut-resistant gloves |
KEY TAKEAWAY: Risk management is a continuous process throughout production, not a one-time pre-production exercise. Students must demonstrate ongoing safety monitoring and responsiveness to changing conditions.
VCAA FOCUS: In Unit 4 SAT, document evidence of active risk management (photographs of PPE in use, notes about hazard re-assessment when plans changed) — this is assessed directly.
