Manufacturing Excellence Through Compliance

Under PUWER 1998, the frequency and type of inspection depends on the risks associated with the equipment and the environment it operates in. There is no single prescribed interval — inspections must occur at suitable intervals, determined by a risk assessment. High-risk equipment in aggressive environments (e.g., presses, conveyors, CNC machines) typically requires more frequent checks than low-risk hand tools. Inspection records must be retained and must identify the equipment, who carried out the inspection, the date, any defects found, and action taken. Assistant Manager lets you create equipment-specific inspection schedules with automated reminders and digital records of every completed check.

COSHH assessments must be documented in writing, must be suitable and sufficient, and must be reviewed when there is reason to believe they are no longer valid (e.g., after a process change, a new substance is introduced, or health surveillance reveals a problem). As a minimum, assessments should be reviewed annually. Each assessment should identify the substance, its hazardous properties (by reference to the Safety Data Sheet), who is exposed, how they are exposed, the controls in place, and any health surveillance required. Assistant Manager enables you to store assessments digitally, link them to substances and work areas, assign review dates, and record employee acknowledgements.

If your site stores dangerous substances (including flammable liquids, toxic chemicals, or explosives) at or above the threshold quantities set out in Schedule 1 of COMAH 2015, you will be a lower-tier or upper-tier COMAH establishment. Lower-tier sites must notify the Competent Authority (HSE and Environment Agency jointly), prepare and implement a Major Accident Prevention Policy (MAPP), and review it every five years. Upper-tier sites additionally must produce a comprehensive Safety Report and on-site emergency plan, which are subject to Competent Authority assessment. Failure to comply is a criminal offence. Check the COMAH threshold quantities for your specific substances using the HSE's online tool.

Lockout/tagout procedures should be documented for every machine or piece of plant that requires isolation before maintenance or cleaning. The procedure must specify every energy source (electrical, pneumatic, hydraulic, stored mechanical energy), the isolation point, the isolation device to use, and the sequence of steps. Before maintenance begins, the Permit to Work or LOTO record must be completed, signed by the authorised person, and physically attached to the isolation point. Assistant Manager can manage digital Permits to Work and LOTO authorisation records, ensuring every isolation is documented, traceable, and cannot be overlooked during shift handovers.

Employers must carry out a noise risk assessment where employees are likely to be exposed at or above the lower exposure action value of 80 dB(A) daily or weekly average. The assessment must identify who is at risk, estimate exposures, identify controls already in place, and determine whether further action is needed. Above the upper action value of 85 dB(A), employers must introduce technical and organisational controls to reduce noise, provide and ensure the use of hearing protection, and establish hearing protection zones. Health surveillance (audiometry) is required for employees regularly exposed at or above the upper action value. Assessments should be reviewed when working conditions change significantly.

HSE manufacturing inspectors typically examine whether your health and safety management system is effectively implemented, not just documented. Key areas include: written risk assessments that reflect actual working conditions; evidence that PUWER and LOLER inspection schedules are up to date; COSHH assessments and monitoring records for significant substances; accident and near-miss records with completed investigations; training records for all employees including machinery operators; and evidence that corrective actions from previous inspections or incidents have been completed. Assistant Manager provides a real-time compliance dashboard showing overdue inspections, outstanding actions, and any gaps — giving you the assurance that you are always ready for an unannounced visit.

ISO 9001:2015 requires organisations to maintain documented information (records) to provide evidence that its processes are being carried out as planned. Key mandatory records include: calibration records for monitoring and measuring equipment; records of competence and training; non-conformance records and the results of corrective actions; results of management reviews; internal audit programme and results; and evidence of customer communication and satisfaction. Beyond the mandatory minimum, most manufacturers also retain production records, inspection and test records, supplier evaluation records, and change control records. All records must be legible, identifiable, and retrievable. Assistant Manager structures these records digitally with search, filter, and export capabilities for audit preparation.

When a RIDDOR-reportable incident occurs, you must report it to the HSE promptly (immediately for deaths and specified injuries; within 10 days for over-7-day injuries; within 15 days for occupational diseases). You must also keep a record of the incident for at least three years. Separately — and regardless of whether RIDDOR applies — a thorough internal investigation should document the sequence of events, immediate and root causes, contributing factors, and corrective actions. Investigation records are essential evidence that you have taken the incident seriously and implemented controls to prevent recurrence, which HSE inspectors will want to review. Assistant Manager provides structured incident report forms, investigation workflows, and action tracking to closure, with automated prompts for RIDDOR reportable thresholds.