NEBOSH

MANAGEMENT OF HEALTH AND SAFETY

UNIT IG1:
For: NEBOSH International General Certificate in Occupational Health and Safety

Open Book Examination

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Answer sheet IG1-0038-ENG-OBE-V1 May24 © NEBOSH 2024 page 1 of 14

Task 1: Auditing approach

Question 1 (a)

1. Previous Accident: The decision to conduct a health and safety audit

instead of an inspection likely stemmed from a serious accident that
occurred six months prior, indicating the need for a comprehensive review
of the entire safety management system rather than a superficial
inspection.
2. Comprehensive Assessment: An audit provides a thorough assessment of
the organisation's adherence to health and safety policies and procedures,
which was necessary to understand the systemic issues at Northern Mill.
3. External Expertise: The involvement of an external health and safety
consultant suggests that an in-depth knowledge and impartial perspective
were required to identify less obvious deficiencies and solutions.
4. Change Implementation: Following the serious accident, there was a clear
intention to overhaul and improve existing safety measures, which would
be more effectively addressed through an audit that examines the
effectiveness of policies and their implementation.
5. Employee Safety Knowledge: The owner's discovery that factory workers
had significant gaps in their health and safety knowledge indicated the
need for an audit to evaluate the effectiveness of training and
communication.
6. Regulatory Compliance: An audit helps ensure compliance with health
and safety regulations, which is critical in a factory setting where the risks
are high.
7. Preventive Approach: The audit aimed at implementing a planned
preventative maintenance program for machinery, which goes beyond the
scope of basic inspections and focuses on proactive risk management.
8. Policy and Procedure Update: The audit was necessary to review and
update the health and safety policies and the risk assessments, ensuring
that they are comprehensive and up-to-date.
9. Continuous Improvement: The audit likely aimed to establish a baseline
for ongoing improvements in health and safety practices at Northern Mill,
fostering a culture of continuous improvement.
10. Stakeholder Assurance: Conducting an audit reassures stakeholders,
including employees and customers, that the organisation is committed to
maintaining a safe working environment.
11. Risk Identification and Mitigation: An audit provides a systematic
approach to identifying, analyzing, and mitigating risks, which is essential in
a complex environment like a textile factory.
12. Feedback Mechanism: The audit facilitates feedback from various levels
within the organisation, including insights from workers and supervisors,
which is crucial for effective health and safety management.

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 13. Documentation and Evidence: An audit helps in documenting processes
and evidence of compliance or non-compliance, which is useful for legal,
regulatory, and managerial purposes.

Question 1 (b)
•
Enhanced Credibility: Utilizing an external auditor lends credibility to the audit results
at Northern Mill, which is critical especially after the serious accident. This external
validation demonstrates to stakeholders, including employees and customers, that the
company is serious about rectifying its health and safety issues.
• Expertise and Specialization: The external auditor brought specific expertise in health
and safety that may not have been available internally. This is particularly important given
the complex textile manufacturing processes at Northern Mill, which require specialized
knowledge to ensure safety standards are met.
• Objective Assessment: An external auditor provides an unbiased perspective, crucial
for accurately identifying safety shortcomings and areas for improvement. This objective
view helps prevent internal biases or conflicts of interest from influencing the audit
findings.
• Compliance with Regulations: External auditors are typically well-versed in the latest
regulations and compliance requirements. Their involvement ensures that Northern Mill's
practices align with legal standards, potentially avoiding fines or legal complications.
• Identification of New Risks: Given the previous accident and the complex nature of
the textile manufacturing process, an external auditor is better positioned to identify
unseen or emerging risks that internal personnel might overlook.
• Staff Training and Awareness: The audit conducted by an external party highlighted
significant gaps in staff knowledge regarding health and safety. This finding likely
influenced the decision to implement mandatory annual refresher training, ensuring that
the workforce remains informed about best safety practices.
• Focus on Core Operations: By outsourcing the audit process, Northern Mill could
maintain focus on its core operational activities. This approach minimizes disruption to
daily operations while still ensuring a thorough and effective safety audit is conducted.

Task 2: Management of risks

Question 2

1. Health and Safety Policy Revision: Northern Mill responded to the

serious accident by revising their health and safety policy, showing a
proactive approach to managing risks and ensuring policies are up-to-date
and relevant.
2. Risk Assessments Update: The company updated the risk assessments for
tasks performed on the factory floor, which is crucial for identifying and
mitigating specific hazards associated with textile manufacturing.
3. Preventative Maintenance Program: Implementing a planned
preventative maintenance program for all machinery helps prevent
accidents related to equipment failure, ensuring that machinery is safe and
operational.

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 4. Annual Refresher Training: Requiring all factory workers to complete
annual refresher training ensures that all employees remain knowledgeable
about current safety practices and procedures.
5. Induction Training Enhancement: Northern Mill redesigned their
induction training to include basic health and safety training, ensuring that
new employees understand the risks and safety procedures from day one.
6. Consultation with Workers: The owner spent time with factory workers to
assess their health and safety knowledge, which helps in tailoring training
and policies to the actual needs and gaps in worker understanding.
7. Employment of a Full-time Health and Safety Adviser: Hiring a
dedicated health and safety adviser ensures ongoing attention to safety
issues, providing a point of contact for safety concerns and ongoing risk
management.
8. Clear Labeling of Machinery: All machines are clearly labeled with names,
load capacities, and basic working instructions, which helps prevent misuse
and informs workers of critical operational limits.
9. Monitoring of Environmental Conditions: The careful monitoring of
temperature and humidity in the drying chambers is a good practice that
helps prevent equipment malfunction and ensures a safe working
environment.
10. Access Control to Factory Floor: Having doors with ‘no unauthorised
access’ signs helps control access to potentially dangerous areas, reducing
the risk of accidents involving untrained or unauthorized personnel.
11. Response to Near Misses: The rapid response and immediate shutdown
of machinery following a near miss incident demonstrate a strong on-the-
ground safety protocol to prevent further accidents.
12. Near Miss Investigation: Following the near miss, a thorough
investigation was initiated, which is critical in understanding what went
wrong and preventing future incidents.
13. Emergency Preparedness: The presence of an emergency stop button on
the machinery and quick action by Supervisor S during the near miss
incident show that emergency measures are in place and accessible.
14. Communication Devices: The use of two-way radios for immediate
communication across the factory floor enhances the ability to quickly
manage risks and respond to emergencies.
15. Employee Empowerment: Despite some resistance, the overall move
towards empowering employees with knowledge and training supports a
culture of safety and risk awareness, which is essential for effective risk
management.

Task 3: Individual factors

Question 3

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 1. Lack of Experience: The new factory worker was unfamiliar with the machinery,
as indicated by their assignment to use a machine they had not previously
operated. This lack of experience with the specific equipment could have
contributed to their inability to recognize the risks involved.
2. Inadequate Training: The scenario suggests that the new factory worker may not
have received comprehensive training on the specific machine before being tasked
with its operation. Inadequate training on how to safely load and operate the
dyeing vessel likely contributed to the incident.
3. Insufficient Induction: Although the induction process was redesigned to include
basic health and safety training, the delivery by Supervisor R was resentful and
possibly incomplete, which may have left the new worker inadequately informed
about the safety protocols.
4. Pressure to Perform: Supervisor R explicitly pressured the new worker to hurry
the process due to a delivery date error, increasing the likelihood of rushing and
bypassing safety procedures to meet deadlines.
5. Fear of Authority: Supervisor R's threat to report the new worker if they did not
comply may have instilled fear, compelling the worker to proceed without seeking
further guidance or assistance, despite their concerns.
6. Lack of Supervision: At the critical moment, the worker was left unsupervised
with the instruction that the next supervisor was "probably around somewhere,"
which might have made them feel they needed to handle the situation alone.
7. Stress and Anxiety: The pressure from being rushed and threatened by Supervisor
R could have increased stress levels, impairing the worker’s judgment and
decision-making ability.
8. Inadequate Risk Assessment: The new factory worker might not have been
trained to assess the risks of overloading the machine properly, a critical step in
safely operating the equipment.
9. Unfamiliarity with Emergency Procedures: The scenario does not specify if the
new worker was familiar with emergency stop procedures or protocols for when a
machine indicates a warning, which is crucial in preventing accidents.
10. Communication Barriers: If there were any language or communication barriers,
these could have further hindered the worker's understanding of the instructions or
safety protocols.
11. Confidence to Challenge Unsafe Orders: The new worker may have lacked the
confidence or felt they did not have the authority to challenge the unsafe order
given by Supervisor R, contributing to the escalation of the situation.
12. Awareness of Safety Signs: It’s unclear if the worker was adequately briefed on
recognizing and responding to safety warnings on machinery, like the overload
warning that flashed on the machine.
13. Physical Readiness: The physical act of reaching into the machine indicates a
lack of understanding of the mechanical hazards, possibly due to not being
physically prepared or aware of the dangers involved in interacting with moving
components.

These factors combined to create a situation where the new factory worker was at a
heightened risk of encountering a near miss due to both a lack of proper training and
support, and the pressure and environment in which they were placed.

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Task 4: Management of near miss

Question 4

1. Quick Action: Supervisor S acted swiftly upon noticing the new factory
worker reaching into the dyeing vessel, which was crucial in preventing a
potential injury.
2. Emergency Stop Activation: Supervisor S promptly pressed the
emergency stop button on the machine, demonstrating a proper response
to the situation and adherence to emergency procedures.
3. Immediate Shutdown of Machine: Ordering the immediate shutdown of
the machine was a decisive action that prevented further use of the
potentially unsafe equipment and eliminated the risk of additional
accidents.
4. Personal Attention to the Worker: Supervisor S took the distressed
worker aside to a quiet room, which shows care for the emotional well-
being of the employee, not just the physical.
5. First Aid Response: As the first-aider on shift, Supervisor S checked the
worker’s wrist for injuries, ensuring that there were no physical harms
overlooked.
6. Effective Use of Communication Tools: Utilizing the two-way radio to
request the owner to supervise the factory floor demonstrated effective use
of communication tools to manage the situation and ensure continuous
oversight.
7. Immediate Reporting to Management: Supervisor S promptly informed
the owner of the incident, ensuring that higher management was aware of
the near miss and could take necessary steps.
8. Handling the Emotional Impact: Sending the new factory worker home to
recover shows an understanding of the psychological impact such incidents
can have, highlighting the importance of mental health alongside physical
safety.
9. Near Miss Investigation: Initiating a near miss investigation with the
owner’s help indicated a structured approach to understanding and
documenting what happened, which is essential for preventing future
incidents.
10. Ensuring Continuous Supervision: By calling the owner to supervise the
floor, Supervisor S ensured that there was no gap in oversight, maintaining
safety until the situation was fully stabilized.

Overall, Supervisor S demonstrated effective crisis management skills that not

only addressed the immediate safety concerns but also the longer-term
implications of the incident on the worker’s well-being.

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Task 5: Procedural controls

Question 5

1. Machine Labeling: Each machine, including the dyeing machine, was

clearly labeled with its name, load capacity limit, and basic working
instructions, providing essential operational information to workers.
2. Health and Safety Policy: The updated health and safety policy at
Northern Mill included procedures and guidelines aimed at ensuring safe
operations across the factory floor.
3. Risk Assessments: Updated risk assessments for tasks on the factory floor
helped in identifying specific risks associated with each piece of machinery,
including the dyeing machines.
4. Preventative Maintenance Program: The planned preventative
maintenance program for all machinery, including the dyeing machines,
ensured that they were kept in good working condition, reducing the risk
of mechanical failures.
5. Training Programs: Mandatory annual refresher training for all factory
workers aimed to keep them informed about operational and safety
procedures specific to their tasks, including those involving the dyeing
machines.
6. Induction Training: New workers received induction training that covered
basic health and safety information and an overview of the factory floor,
intended to familiarize them with equipment like the dyeing machines.
7. Supervisory Oversight: The presence of supervisors like Supervisor S, who
are knowledgeable about the machines and safety protocols, helped in
managing the risks associated with machine operations.
8. Emergency Procedures: Emergency stop buttons on machines, including
the dyeing machine, provided a quick means to halt operations in case of
an emergency.
9. Access Control: The factory had controlled access points with signs
indicating "no unauthorized access," helping to restrict access to the
dyeing machines to trained and authorized personnel only.
10. Clear Communication: The use of two-way radios facilitated immediate
communication across the factory floor, allowing for quick response and
coordination in case of an incident.
11. Employee Empowerment: Workers were encouraged to report unsafe
conditions and participate in safety discussions, which could include issues
with the dyeing machines.
12. Monitoring and Inspection: Regular checks and monitoring of the dyeing
machines' conditions and operations as part of the overall safety
management system ensured that any deviations from normal operations
could be addressed promptly.

These procedural controls collectively aimed to minimize the risks associated with
operating the dyeing machines at Northern Mill, although the effectiveness of

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 these measures depends significantly on proper implementation and adherence
by all personnel.

Task 6: Policy implementation

Question 6
Based on the scenario provided, here are the points detailing how Northern Mill
has implemented the revised health and safety policy over the past six months:

1. Preventing Accidents and Near Misses: The organization has undertaken

a series of actions to minimize accidents and near misses, notably through
updating equipment and procedures.
2. Investigating Accidents and Near Misses: Following the near miss
incident, there was immediate action to investigate, indicating a
commitment to understanding and preventing future occurrences.
3. Providing Safe and Healthy Working Conditions: The efforts to revise
procedures and train staff indicate a move towards safer and healthier
working conditions.
4. Providing Safe Plant and Equipment: The implementation of a planned
preventative maintenance program for all machinery supports this policy
component by ensuring equipment is kept in safe working order.
5. Setting and Reviewing Health and Safety Objectives: The owner’s
proactive approach, including the employment of a full-time health and
safety adviser, suggests that setting and reviewing safety objectives is a
continuous process at Northern Mill.
6. Identifying Health and Safety Hazards and Risks: The updated risk
assessments for factory tasks demonstrate the organization’s commitment
to identifying potential hazards and risks.
7. Providing Adequate Training: The requirement for all factory workers to
complete annual refresher training and the redesign of the induction
training to include health and safety elements show a commitment to
providing adequate training.
8. Providing Health and Safety Information to Workers: The distribution
of printed copies of the health and safety policy to new workers, although
done resentfully by Supervisor R, aligns with this policy aspect.
9. Involving Workers: The owner’s consultations with factory workers to
assess their knowledge and involvement in safety practices reflect a
commitment to involving workers in safety management.
10. Provision of Resources: Hiring a full-time health and safety adviser and
the actions taken to enhance safety training and equipment maintenance
demonstrate the provision of resources required to make the policy
effective.

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 11. Communication and Enforcement of Safety Procedures: The use of clear
labeling on machines and the enforcement of safety procedures by
supervisors like Supervisor S show policy implementation.
12. Emergency Preparedness: The presence of emergency stop buttons and
quick responses in emergencies indicate readiness and safety provision.
13. Monitoring and Control: Regular monitoring of environmental conditions
like temperature and humidity in specific areas ensures adherence to safety
standards.
14. Access Control: Restrictive access to the factory floor ensures that only
authorized and trained personnel engage with machinery, reducing the risk
of accidental injuries.
15. Health and Safety Audits: The engagement of an external auditor to
assess the health and safety standards at the factory indicates an ongoing
commitment to policy compliance and improvement.
16. Worker Feedback: Encouraging feedback from workers during training
sessions and safety meetings shows a dedication to continuous
improvement and worker involvement.
17. Documentation and Record Keeping: Keeping detailed records of
training, maintenance, and safety incidents as part of the policy
implementation is evident.
18. Cultural Change: Efforts to change the safety culture at Northern Mill,
though facing some resistance, signify an overarching commitment to the
policy.
19. Responsiveness to Incidents: The prompt response to the near miss
incident, involving immediate action and investigation, showcases effective
incident management.
20. Leadership and Management Commitment: The owner’s active role in
revising safety policies, engaging with employees, and overseeing
implementations reflects strong leadership in promoting workplace safety.

These points illustrate Northern Mill's extensive efforts to implement its revised
health and safety policy, reflecting a comprehensive and proactive approach to
enhancing workplace safety over the past six months.

Task 7: Workers’ duties in the workplace

Question 7
Based on the scenario provided for Northern Mill, here are points highlighting
areas where workers may not have fully cooperated with their employer in
fulfilling the obligations under ILO Recommendation No. 164:

1. Supervisor R’s Attitude: Supervisor R has been vocal about their belief
that the changes in health and safety management are a waste of time and

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 money, which indicates a lack of cooperation with the employer’s efforts to
enhance safety.
2. Resentful Induction Training: Supervisor R gave the induction resentfully
and merely handed out printed copies of the health and safety policy,
suggesting inadequate delivery of essential safety information and poor
cooperation in ensuring new workers are properly trained.
3. Encouraging Risky Behavior: Supervisor R instructed a new factory worker
to rush a task, prioritizing speed over safety, which goes against the
employer’s safety policies and shows a lack of cooperation in maintaining a
safe working environment.
4. Lack of Supervision: Leaving a new worker unsupervised with machinery
they were unfamiliar with reflects a failure to cooperate with safety
protocols designed to ensure worker safety.
5. Threatening Behavior: Supervisor R’s threat to report the new worker if
they did not comply with unsafe instructions demonstrates a disregard for
cooperative safety practices and creates a hostile environment that can
discourage safe working practices.
6. Ignoring Safety Warnings: When the new factory worker started the
dyeing machine and it indicated an overload, Supervisor R had already left,
showing a lack of cooperation in overseeing that operations were carried
out safely and according to procedure.
7. Inadequate Communication: Supervisor R’s insufficient communication
about the whereabouts of the next supervisor (Supervisor S) and proper
handover protocols further illustrates a lack of cooperation in ensuring
continuous safety oversight.
8. Failure to Follow Emergency Protocols: There’s an indication that not all
workers might be fully cooperating in emergency preparedness, as seen in
the new worker’s initial reaction to the machine warning before Supervisor
S intervened.
9. Resistance to Policy Changes: General resistance among some workers to
the new safety policies and procedures could indicate a broader issue of
non-cooperation that might undermine safety efforts at the factory.
10. Lack of Engagement in Safety Training: If other workers share Supervisor
R’s sentiments about the value of safety training, this could lead to poor
engagement in safety programs, which is crucial for effective
implementation of safety measures.
11. Non-adherence to Safe Work Practices: The scenario implies that there
may be a lack of cooperation in consistently following safe work practices,
particularly in adhering to load capacities and operational procedures for
machinery.
12. Reluctance to Report Safety Issues: There could be a culture among
some workers of not reporting safety issues or near misses, influenced by
attitudes like those of Supervisor R, which hampers the employer’s ability
to address and rectify such issues effectively.

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 13. Impact on Safety Culture: The attitudes and behaviors exhibited by
Supervisor R, if reflective of a wider sentiment among the workforce,
suggest a significant challenge in fostering a cooperative and proactive
safety culture at Northern Mill.

These points highlight the need for continued efforts in promoting cooperation
and compliance with safety regulations and policies among all workers at
Northern Mill to ensure a safe and healthy workplace.

Task 8: Benefits of worker involvement

Question 8

Involving Northern Mill's factory workers in workplace health and safety can yield
significant benefits, as suggested by elements from the scenario:

1. Improved Safety Awareness: Engaging workers in safety discussions and

training could help enhance their understanding of safety practices, leading
to better awareness and application of safety measures.
2. Enhanced Compliance with Safety Protocols: Workers who are involved
in the development and implementation of safety protocols are more likely
to comply with these measures, as they have a clearer understanding of
their purpose and importance.
3. Increased Safety Ownership: When workers are actively involved in health
and safety, they often develop a sense of ownership over their work
environment, which can motivate them to maintain and promote safety
standards.
4. Better Risk Identification: Workers on the factory floor have firsthand
experience with the operations and potential hazards. Their involvement
can lead to more accurate identification of risks and practical suggestions
for mitigating them.
5. Faster Response to Safety Issues: Workers involved in safety processes
are more likely to quickly identify and respond to safety issues, preventing
accidents and near misses.
6. Reduced Resistance to Changes: As seen with Supervisor R’s resistance,
involving workers in the safety process can reduce skepticism and
resistance to new policies and changes, fostering a more accepting attitude
towards safety initiatives.
7. Empowerment through Knowledge: Training and involving workers in
safety practices empowers them with the knowledge to operate safely and
effectively, contributing to overall workplace safety.
8. Cultural Shift towards Safety: Worker involvement can help shift the
factory culture towards one that prioritizes safety, where all employees
actively contribute to a safer workplace.

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 9. Improvement in Safety Innovations: Workers involved in safety may
provide innovative ideas for improving safety based on their daily
experiences with the machinery and processes.
10. Enhancement of Teamwork and Morale: Collaborative safety efforts can
improve teamwork and morale among workers, as they see that their input
is valued and that their well-being is a priority.
11. Reduction in Accidents and Injuries: With better adherence to safety
practices and an increased awareness of potential hazards, the rate of
accidents and injuries can significantly decrease.
12. Increased Productivity: A safer work environment reduces downtime
caused by accidents and injuries, leading to more consistent production
and efficiency.
13. Enhancement of Company Reputation: A company that actively involves
its workers in health and safety can enhance its reputation as a responsible
employer, which can be beneficial for customer relations and employee
recruitment.

These potential benefits highlight the importance of actively involving workers in

the safety processes at Northern Mill, particularly in light of the recent safety
initiatives and challenges faced by the organization

Task 9: Learning lessons from adverse events

Question 9
Learning lessons from adverse events such as the near miss at Northern Mill is
crucial for multiple reasons, all aimed at improving workplace safety and
operational efficiency:

1. Preventing Recurrence: Learning from incidents ensures that the causes

of the near miss are addressed, preventing similar events from occurring in
the future.
2. Improving Safety Standards: Each incident provides valuable insights into
potential weaknesses in safety protocols, offering opportunities to
strengthen these measures.
3. Enhancing Worker Protection: Understanding and addressing the factors
that led to the near miss helps protect workers from potential injuries,
creating a safer work environment.
4. Compliance with Regulations: Learning from incidents helps ensure
compliance with health and safety regulations, which can prevent legal and
financial consequences.
5. Reducing Costs: Incidents often lead to direct and indirect costs, such as
medical expenses, equipment damage, and downtime. Learning from these
can reduce future costs.

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 6. Increasing Worker Confidence: Workers are more likely to feel safe and
valued when they see that the company takes incidents seriously and
makes efforts to prevent them.
7. Building a Safety Culture: A commitment to learning from adverse events
helps foster a culture of safety where all employees are encouraged to
contribute to safety initiatives.
8. Maintaining Reputation: The company can maintain or enhance its
reputation by effectively managing and learning from safety incidents,
showing responsibility and commitment to safety.
9. Enhancing Training Programs: Insights from incidents can be used to
improve training programs, making them more relevant and effective at
preventing similar occurrences.
10. Facilitating Continuous Improvement: Regularly analyzing incidents and
near misses is part of a continuous improvement approach to workplace
safety and operational processes.
11. Empowering Employees: Involving employees in the analysis and solution
development for safety incidents empowers them and can lead to more
effective safety solutions.
12. Supporting Effective Risk Management: Understanding incidents helps
refine risk assessment and management strategies, aligning them more
closely with the actual challenges encountered in the workplace.
13. Improving Communication: The process of addressing incidents often
involves enhanced communication between management and workers,
which can improve overall workplace relations and safety awareness.
14. Documenting Experiences: Documenting what is learned from safety
incidents provides a valuable historical record that can be referred to in the
future to prevent similar situations.
15. Encouraging Proactivity: Learning from incidents promotes a proactive
approach to safety, where potential issues are addressed before they lead
to accidents.
16. Aligning with Best Practices: Each incident analysis provides an
opportunity to align more closely with industry best practices, ensuring
that operations remain current with the most effective safety standards.

For Northern Mill, addressing and learning from the recent near miss not only
mitigates immediate safety risks but also contributes to long-term operational
stability and workforce well-being.

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 Documents and sources For example: course notes, HSG245
of information you used
in your examination

End of examination

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Assessment - Technical Learner Guide, English. All guidance documents can be found on
the NEBOSH website:
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