Plant and Machinery Maintenance Repair and Overhaul Risk Assessment

Product Overview

This risk assessment covers maintenance, repair and overhaul activities for plant, including planning, isolation, work coordination, hazardous energies and emergency response. It supports planning and risk management by addressing responsibilities, communication, plant information, competence, change management and control verification.

Activities & Risks Covered

This assessment addresses activities and risks including:

• Assign responsibilities and review risks as plant conditions, workloads or arrangements change
• Consult workers and coordinate handovers, shared work areas and changing plant status
• Assess site-specific maintenance risks, stored energy and simultaneous activities
• Plan inspections, servicing, repairs, isolation and return to service
• Confirm worker competency, authorisation and suitable supervision for the work
• Review plant information, replacement parts, tools and chemicals before use
• Coordinate contractor, subcontractor and site personnel activities
• Manage hazardous energies, substances, testing, fault finding and temporary energisation
• Prepare for entrapment, fire, electric shock, chemical exposure and plant failure
• Maintain current procedures, permits, drawings, registers and records, and review recurring defects

Who is this for?

For contractors, workers, supervisors and businesses carrying out plant maintenance, repair and overhaul activities.

Activities & Hazards Covered

Legislation & References

The template records model guidance used to inform the documented controls. Applicable WHS/OHS laws and adopted Codes vary by state or territory, so confirm the current local requirements when tailoring the assessment:

• Model guidance: Model Code of Practice: Managing risks of plant in the workplace — Assessing plant risks — work practices and procedures; p. 20.
• Model guidance: Model Code of Practice: Managing risks of hazardous chemicals in the workplace — 2.1 How to identify which chemicals are hazardous; p. 15.
• Model guidance: Model Code of Practice: How to manage work health and safety risks — 5. Step 4 — How to review controls; p. 27.
• Model guidance: Model Code of Practice: First aid in the workplace — 3. First aid equipment, facilities and training; p. 12.
• Model guidance: Model Code of Practice: Managing the risk of falls at workplaces — 3.2 Identifying the hazards; p. 16.
• Model guidance: Model Code of Practice: Work health and safety consultation, cooperation and coordination — 3. What is effective consultation?; p. 13.
• Model guidance: Model Code of Practice: Hazardous manual tasks — 4.1 The hierarchy of control measures; p. 31.
• Model guidance: Model Code of Practice: Managing electrical risks in the workplace — 5. Isolation, locking off and access; p. 34.

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Standard Risk Assessment Features (Click to Expand)

• Activity-specific hazard identification and control measures
• Initial and residual risk ratings
• Assigned responsible persons for each activity
• Risk matrix and assessment classification
• Review, monitoring and sign-off fields
• Site-specific customisation before use