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Manufacturing Risk Assessment — Generated Instantly for £29
Describe the factory process, machinery, materials, and working environment. We generate a fully written, UK-compliant manufacturing risk assessment covering PUWER, manual handling, COSHH, noise, and all relevant regulations in minutes.
Used by manufacturing managers, production supervisors, facilities teams, and health & safety officers across UK factories
⚙️ Operating dangerous machinery? Mention the specific equipment (presses, lathes, conveyors, CNC machines) and we'll include PUWER-compliant guarding requirements, lockout/tagout procedures, and emergency stop controls in your assessment.
Legal requirements for manufacturing risk assessments
Manufacturing is one of the highest-risk sectors in the UK. According to HSE statistics, the manufacturing sector accounted for 22 workplace fatalities in 2022/23 and over 58,000 non-fatal injuries. The legal framework governing manufacturing safety is comprehensive and strictly enforced.
The Health and Safety at Work Act 1974 requires all employers to ensure, so far as is reasonably practicable, the health, safety, and welfare of employees. Section 2(3) requires a written health and safety policy for organisations with five or more employees, and this must be based on adequate risk assessments.
The Management of Health and Safety at Work Regulations 1999 impose a specific duty to carry out risk assessments. Regulation 3 states that every employer must make a suitable and sufficient assessment of the risks to workers and others affected by their undertaking. For manufacturing, this means assessing machinery hazards, manual handling, chemical exposure, noise, vibration, and environmental risks such as heat, dust, and confined spaces.
The Provision and Use of Work Equipment Regulations 1998 (PUWER) is critical in manufacturing. Regulation 11 requires that dangerous parts of machinery are effectively guarded or protected. Regulation 16 mandates that control systems (emergency stops, interlocks, guards) prevent exposure to danger. PUWER applies to all machinery — from hand tools to fully automated production lines — and non-compliance is a common cause of HSE enforcement action.
The Manual Handling Operations Regulations 1992 require employers to avoid hazardous manual handling where reasonably practicable, and where it cannot be avoided, to assess the risk and reduce it to the lowest level reasonably practicable. In manufacturing, this applies to lifting materials, moving components, and repetitive assembly work.
The Control of Substances Hazardous to Health Regulations 2002 (COSHH) require risk assessments for exposure to chemicals, fumes, dusts, and biological agents. Manufacturing processes frequently involve cutting fluids, solvents, adhesives, metal dust, and welding fumes — all of which require COSHH assessment and documented controls.
The Control of Noise at Work Regulations 2005 and Control of Vibration at Work Regulations 2005 impose action and limit values for noise and vibration exposure. Manufacturing environments with presses, grinders, drills, and pneumatic tools must assess exposure levels and implement controls such as hearing protection zones, engineering controls, and tool rotation schedules. A written risk assessment is mandatory where exposure action values are exceeded.
How it works
1. Describe the manufacturing process
Tell us the type of manufacturing (assembly, fabrication, machining, food production), the machinery and equipment used, materials handled, chemicals or dusts generated, noise levels, and any specific hazards such as confined spaces, hot work, or working at height. The more detail you provide, the more tailored and accurate the assessment.
2. Your assessment is generated instantly
Anyrisks produces a fully written, UK-compliant manufacturing risk assessment referencing PUWER 1998, MHSWR 1999, COSHH 2002, Manual Handling Regulations 1992, and all other relevant regulations. The assessment includes hazard identification, risk ratings, and specific control measures tailored to your factory environment.
3. Download, use, and file
Download as PDF and editable Word document. Use it for ISO 45001 audits, HSE inspections, induction training, or contractor RAMS packs. Update it as your processes change. £29, no subscription, money-back guarantee within 24 hours if you're not satisfied.
What it covers
Every manufacturing risk assessment is written in full — covering all machinery, process, and environmental hazards relevant to your factory.
Machinery hazards — guarding, interlocks, emergency stops (PUWER 1998)
Manual handling — lifting, carrying, repetitive tasks (Manual Handling Regulations 1992)
COSHH — chemicals, solvents, cutting fluids, metal dust, fumes (COSHH 2002)
Noise exposure — machinery noise, hearing protection zones (Control of Noise at Work 2005)
Vibration exposure — hand-arm and whole-body vibration (Control of Vibration at Work 2005)
Slips, trips, and falls — wet floors, trailing cables, uneven surfaces
Working at height — access to machinery, mezzanine floors, racking
Hot work — welding, grinding, cutting, flame treatment
Confined spaces — tanks, silos, chambers, pits
Lockout/tagout procedures — machinery isolation during maintenance
Electrical safety — control panels, power tools, temporary supplies
Fire and explosion risk — flammable materials, dust, hot work
Forklift and mobile plant movements — segregation, reversing alarms
Lone working — night shifts, isolated maintenance tasks
Works for every type of manufacturing
From automotive assembly lines to food production kitchens, Anyrisks covers every manufacturing environment and process.
What customers say
"We run a metal fabrication shop with lathes, presses, and welding bays. Anyrisks covered PUWER, COSHH for welding fumes, and manual handling — exactly what our ISO 45001 auditor wanted to see."
David K.
Operations manager, engineering firm, West Midlands
"Our production line has conveyors, packaging machinery, and forklift movements. The assessment covered guarding, emergency stops, and segregation — HSE inspector was satisfied with the format and detail."
Linda M.
Health & safety officer, food manufacturer, Yorkshire
"We needed a COSHH assessment for cutting fluids and metal dust in our CNC workshop. Anyrisks included ventilation requirements, PPE specs, and exposure monitoring schedules — complete in under 2 minutes."
Rajesh P.
Workshop supervisor, precision engineering, East Anglia
Anyrisks vs DIY templates
| Anyrisks | DIY / Templates | |
|---|---|---|
| Written in full — not a blank form | ✓ | ✗ |
| PUWER 1998 machinery guarding requirements | ✓ | ✗ |
| COSHH 2002 chemical and fume controls | ✓ | ✗ |
| Manual Handling Regulations 1992 compliance | ✓ | ✗ |
| Noise and vibration exposure controls | ✓ | ✗ |
| Lockout/tagout and isolation procedures | ✓ | ✗ |
| Ready in under 2 minutes | ✓ | ✗ |
| Instant PDF and Word download | ✓ | Sometimes |
Frequently asked questions
Does this cover PUWER and machinery guarding requirements?
Yes — manufacturing risk assessments include PUWER 1998 compliance, machinery guarding, emergency stop controls, and all safety interlocks relevant to the machinery you describe. The assessment references Regulation 11 (dangerous parts of machinery) and Regulation 16 (controls and control systems) where applicable.
Can I use it for both production lines and workshop environments?
Yes — describe the manufacturing environment (production line, CNC workshop, fabrication shop, assembly area) and the specific processes, and the assessment will be tailored accordingly. Different manufacturing settings have different hazard profiles and the assessment reflects this.
Does it cover manual handling and repetitive strain injury risks?
Yes — mention any heavy lifting, repetitive assembly tasks, or awkward postures and the assessment will include manual handling controls under the Manual Handling Operations Regulations 1992, including mechanical aids, rotation schedules, and ergonomic workstation design.
Is COSHH covered for manufacturing chemicals and dust?
Yes — describe any chemicals, lubricants, solvents, cutting fluids, metal dust, or fumes generated during manufacturing processes. The assessment will include COSHH controls, ventilation requirements, PPE specifications, and reference the Control of Substances Hazardous to Health Regulations 2002.
Does it cover noise and vibration exposure?
Yes — if you operate loud machinery (presses, grinders, CNC machines) or vibrating tools, mention it. The assessment will include noise exposure controls under the Control of Noise at Work Regulations 2005 and vibration controls under the Control of Vibration at Work Regulations 2005, including hearing protection zones and tool rotation schedules.
Can I use this for ISO 45001 or ISO 9001 certification?
Yes — manufacturing risk assessments produced by Anyrisks follow the hazard identification and control structure expected by ISO 45001 (occupational health and safety) and ISO 9001 (quality management) auditors. The format is professional, regulation-referenced, and accepted across UK manufacturing.
Does it cover heat, welding fumes, and confined spaces in factories?
Yes — describe any hot work (welding, grinding, cutting), confined space entry (tanks, silos, chambers), or work in high-temperature environments. The assessment will include specific controls for each hazard, including hot work permits, fume extraction, and confined space rescue procedures.
How quickly can I get the assessment?
Under 2 minutes. Describe the manufacturing process, machinery, materials, and working environment, and Anyrisks produces a complete, regulation-referenced manufacturing risk assessment instantly.
Also see: The Ultimate Guide to Risk Assessment · Do I Need a Risk Assessment? · Risk Assessment Legal Requirements · Risk Assessment Generator