3.2 Identifying Hazards

Scene: Shop Floor – Liza Coaching John During a Task
[Sound: light background noise of tools and machines. John stands near a workbench with tools. Liza observes him.]
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John:
Liza, I’ve done this job a hundred times. Isn’t it enough to just know the general hazards?
Liza:
Not always. A general look can miss critical risks. The real key is to break the job down—step by step—and look for hazards in each micro-movement.
John:
Microsteps? You mean like a task checklist?
Liza:
Exactly. Let’s go through it together.
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Liza - Section 1 is - Why Microsteps Matter
• Hazards often hide in the smallest parts of a task.
• Breaking tasks into microsteps helps uncover specific, less obvious dangers.
• This method supports better risk assessment, controls, and training.
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Liza Section 2 is The Breakdown Method (Think: What / How / With What)
Ask these questions for each activity:
1. What am I doing?
2. How am I doing it?
3. With what tools, materials, or equipment?
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Liza - John hope you understand how we have to do breakdown of steps.
John - Yes liza but can we have a real example.
Liza - Yes off course, let us take a example of Changing a Machine Blade
Let’s break it down into microsteps:
On screen table and activity

Microstep Potential Hazards
Turn off the machine Electrical shock if lockout/tagout not used
Remove the machine guard Pinch points, sharp edges, dropped parts
Unscrew blade with a wrench Slips, muscle strain, flying parts if under tension
Handle the old blade Cuts from sharp edges
Dispose of old blade Improper disposal = injury to others
Install new blade Improper alignment = future malfunction
Re-tighten and test Vibration, mechanical failure if not tested safely

Liza:
See how each small step has its own risks? If you just say “change blade,” you miss most of these.
John:
Got it. “One task” can actually hide five different hazards.

Practical Case 1 - Shifting Box
Video 9
Liza - John create a micro step for Moving a heavy box from storage to a table
But before you start here are the Practical Tips for Microstep Hazard ID
✅ Think in actions, not outcomes (e.g., “grabbing handle” vs. “opening valve”)
✅ Observe others doing the task — what tiny movements are involved?
✅ Check posture, repetition, tools used, environmental conditions
✅ Ask: “What could go wrong here?” at every step
John - Thank you Liza for the practical tips let me prepare the steps now.
Activity: Moving a heavy box from storage to a table
On screen table and activity

Microstep Potential Hazards
Walk to storage area Hazards: Slippery floor, poor lighting
Bend to lift box Hazards: Back strain, bad posture
Grip the box Hazards: Sharp edges, loose flaps, poor grip
Carry box to table Hazards: Obstructed path, fatigue, dropped load
Place on table Hazards: Pinched fingers, sudden slip

Closing Scene: Back to the Floor
John:
Okay, this is way more detailed than I thought. But I can see how it keeps people safer.
Liza: - Exactly. One small hazard missed is all it takes for an injury. Break it down, spot the risks, and you stay ahead.