OHS Gap Analysis in a Steel Mill

“SteelWorks”., a major player in the steel manufacturing industry, recognized the need to enhance its Occupational Health and Safety (OHS) management system. The company aimed to conduct a comprehensive gap analysis focusing on 11 critical pillars of safety: confined space, contractor management, cranes and lifting, electrical control program, gas hazards, guarding, lone worker, molten metal, PPE, railway, and working at heights.

• Identify gaps in the current OHS management system across the 11 safety pillars.
• Develop actionable recommendations to address identified gaps and improve overall safety performance.
• Ensure compliance with relevant OHS regulations and industry best practices.

Our approach involved a detailed assessment of their safety practices, policies, and procedures. The following steps were undertaken:

1. Initial Assessment and Data Collection

• Conducted site inspections, employee interviews, and document reviews to gather information on existing safety practices.
• Reviewed incident reports and safety records to identify trends and areas of concern.

2. Gap Analysis for Each Safety Pillar

• Confined Space: Assessed the adequacy of confined space entry procedures, training, and emergency response plans.
• Contractor Management: Evaluated contractor pre-qualification processes, safety training, and performance monitoring.
• Cranes and Lifting: Reviewed lifting equipment inspection records, operator training, and lifting procedures.
• Electrical Control Program: Examined electrical safety policies, lockout/tagout procedures, and employee training.
• Gas Hazards: Assessed gas detection systems, ventilation, and emergency response plans for gas leaks.
• Guarding: Evaluated machine guarding practices, risk assessments, and employee training on guarding.
• Lone Worker: Reviewed lone worker policies, communication systems, and emergency response procedures.
• Molten Metal: Assessed safety measures for handling molten metal, including PPE, training, and emergency response.
• PPE: Evaluated the adequacy and use of personal protective equipment across various tasks.
• Railway: Reviewed railway safety procedures, employee training, and incident response plans.
• Working at Heights: Assessed fall protection systems, training, and rescue plans for working at heights.

3. Development of Actionable Recommendations

• Created a detailed report outlining identified gaps and specific recommendations for each safety pillar.
• Prioritized recommendations based on risk severity and potential impact on employee safety.

4. Implementation and Training

• Assisted them in strategic and action plans for addressing the GAP’s identified in each of the 11 pillars.
• Conducted training sessions for keystakeholders, the OHS department and senior leadership on findings, strategic and action plan strategies and their roles within each.

1. Enhanced Safety Performance

• Achieved significant improvements in safety practices across all 11 pillars.
• Reduced incident rates and improved employee adherence to safety protocols.

2. Improved Safety Culture

• Fostered a proactive safety culture through continuous training and engagement.
• Increased reporting of near-misses and potential hazards, leading to timely interventions.

3. Compliance and Recognition

• Ensured compliance with relevant OHS regulations and industry standards.
• Received positive feedback from regulatory bodies during safety inspections and audits.

The OHS gap analysis. successfully identified and addressed critical safety issues across the 11 pillars of safety. By implementing a structured safety improvement plan and fostering a culture of safety, the company significantly enhanced its operational safety and employee well-being. This case study demonstrates the value of expert OHS consulting in transforming safety practices and achieving sustainable improvements in high-risk environments.