Common Safety Issues

  • A proactive HSE Audit helps identify risks before they become incidents — saving time, money, and reputation.
  • Here are four common issues discovered during HSE Audits — and how we helped each company become safer, stronger, and fully compliant.

Inadequate Risk Assessments

Problem:

A small fabrication workshop had no formal risk assessments for welding, grinding, or manual handling — breaching the Management of Health and Safety at Work Regulations 1999.

Action:

We created clear, task-based risk assessments, introduced control measures, and trained supervisors and staff on safe systems of work.

Result:

Accidents and near misses dropped by over 50%, and the business achieved full compliance — with a stronger safety culture across the team.

Fire Safety Gaps and Outdated Procedures

Problem:

A medium-sized engineering firm had blocked fire exits, expired extinguishers, and no recent drills — non-compliant with the Regulatory Reform (Fire Safety) Order 2005.

Action:

We completed a detailed fire risk assessment, updated emergency signage, cleared escape routes, and trained staff as fire marshals.

Result:

The company passed its follow-up inspection, improved staff confidence, and met insurer requirements for safety management.

Unsafe Machinery and Missing Maintenance Records

Problem:

A small manufacturing site operated several machines without current PUWER inspections. Some lacked proper guarding, and no maintenance logs were available.

Action:

We introduced a preventative maintenance schedule, replaced missing guards, and trained operators on pre-use checks and safe operation.

Result:

All equipment met statutory standards, downtime was reduced, and the company avoided potential enforcement notices.

Inadequate Training and Competence Records

Problem:

A construction subcontractor had workers handling materials and chemicals without any formal training or competence evidence — breaching HASAWA Section 2(2)(c).

Action:

We delivered practical training in manual handling, PPE, and COSHH awareness, and established a competency and refresher matrix.

Result:

The company demonstrated legal compliance, reduced injuries, and improved overall workforce confidence.

Build a Safer Compliant Workplace

A proactive HSE Audit helps identify risks before they become incidents — saving time, money, and reputation.

At KG Health & Safety Consultancy and Training, we provide practical, hands-on support through audits, inspections, risk assessments, and training that keep your business compliant and your people safe.

Contact us today to book your audit or discuss how we can support your compliance journey.