Doc. No.

E/RA/01 Punyam Chemicals Limited

Issue No. 01
Date : 01-08-2014 Risk Analysis
Attributes Legal /
Sr. Magnitude Significance
Activity Aspect Risk Customer Present controls / Mitigation plan
No. A B C of Risks level
Concern
To develop alterante market and
1 Overall market scenario Competition Loss of customer 1 5 1 5 No Low penetrate the other area to sustain in
the market
To motivate the employees and to
involve emeployees in day to day
2 Higher emeployee turnover Loss on productivity 2 5 1 10 No Low
work. To introduce the incentive
scheme to retain the employee
To decide policy on pending
payments and accordicngly prioritize
Higher pending payment / Recource crunch /
3 Company level activities 1 4 1 4 No Low the delivery schedule. Also to keep
Payment recovery Financial problem
some reserve to prevent financial
problem
Resolve issues immediately and
Bad impression in
maintain always healthy relation with
4 Legal issues market / Loss of 1 5 5 25 Yes Low
customer to retain customers due to
major customers
legal issues.
Mis-understanding the Quality product can To educate marketing team for
5 1 3 5 15 Yes Low customer requirements and always
requirements not be delivered
keep product requirements on written,
which company can provide to its
Quality product can
6 Requirements are not clear 1 3 5 15 Yes Low customer to avoid mistakes at later
not be delivered
Review of requirements of stage
customer Application of product not To keep document ready for the
7 Product rejection 1 2 5 10 Yes Low
clear different application of products.
To plan always considering the
Delivery requirements not capacity. As well as to keep provision
8 Loss of customer 1 2 5 10 Yes Low
clear for outsourcing in case of over
booking of orders.
Doc. No. E/RA/01 Punyam Chemicals Limited
Issue No. 01
Date : 01-08-2014 Risk Analysis
Attributes Legal /
Sr. Magnitude Significance
Activity Aspect Risk Customer Present controls / Mitigation plan
No. A B C of Risks level
Concern
To document specifications and must
Supply of wrong
9 Specifications not clear 1 2 5 10 Yes Low be conveyed to customer to prevent
products
problem at later stage
To document types of packing
Packing requirements not Loss of product requirements and to document the
10 1 3 5 15 Yes Low
clear during transportation same to prevent packing related
problems.
Review of requirements related To confirm the shipping marks with
11 to product Shipping marks not clear Product rejection 1 3 5 15 Yes Low the customer before acceptance of
order
To provide list of banned chemicals to
the customers and production team
12 Use of banned chemicals Legal non-comliance 1 4 5 20 Yes Low
and to inform purchase team for not
to procure such chemicals
To confirm the test requirements in
13 Test requirements not clear Product rejection 1 4 5 20 Yes Low
writing
To make provision for out sourcing to
Failure in timely
14 Improper prioritization 1 3 5 15 Yes High comply with the customer
supply
requirements
To keep alternate source of supply
Failure in achieving and always keep 2 suppliers in
15 Shortage of raw materials 1 2 5 10 Yes High
Review of customer orders and production plan Approved Vendor list for identified raw
preparation of production materials
planning To plan always considering the
Non-fulfilment of
capacity. As well as to keep provision
16 Improper planning planned 2 3 5 30 Yes High
for outsourcing in case of over
requirements
booking of orders.
Customer requirements not To keep all the requirements always
17 Loss of customer 2 3 5 30 Yes High
understood clearly in written agreement
Spillage due to damages to Always keep extra packages to avoid
18 Resource depletion 1 2 1 2 No Low
packages resource depletion
Collection of raw materials and To do proper preservation of all
Use of expired / non- Non-conforming
19 charging of raw materials in the 1 4 1 4 No Low materials and to keep provision for
moving chemicals product generation
reactor for manufacturing of raw materials from alternate sources
products
To use PPEs always. As well as
20 Direct contact with human Health hazards 1 3 5 15 Yes High contacts are made with the Hospitals
for emergenct treatment
 Doc. No. E/RA/01 Punyam Chemicals Limited
Issue No. 01
Date : 01-08-2014 Risk Analysis
Attributes Legal /
Sr. Magnitude Significance
Activity Aspect Risk Customer Present controls / Mitigation plan
No. A B C of Risks level
Concern
Emergency stop switches are
Increase in temperature Non-conforming provided to stop the heating as well
21 1 4 1 4 No Low
due to improper control product generation as valves are provided to stop the
steam / fuel supply to prevent supply.
Non-conforming products are used in
Non-conforming
22 1 4 5 20 Yes High the alternate application by down
product generation
gradation etc.
Increase in pressure due to
improper control Safety valves and pressure switches
Damages to property
23 1 4 5 20 Yes High are provided and are checked
Manufacturing of product by / resource depletion
periodically to prevent such hazards.
chemical reaction
Increase in acidity / Non-conforming products are used in
Non-conforming
24 alkalinity in the mass due to 2 2 1 4 No Low the alternate application by down
product generation
improper control gradation etc.
System is developed to control
Loss of product /
25 Evaporation of product 1 4 5 20 Yes High evaporation and collection of
resource depletion
evaporated products to prevent loss
System is developed to control
Loss of product /
26 Overflow from reactor 1 4 5 20 Yes High overflow and collection of overflow
resource depletion
products to prevent loss
Press cake Set of new filter cloth are always kept
contamination, in stock. Non-conforming product is
27 Contaminated filter cloth 2 3 1 6 No Low
leading to non- used in alternate application or
conforming product downgraded
Set of new filter cloth are always kept
Loss of product in
in stock. Mother liquor is collected
28 Damaged filter cloth mother liquor / 1 2 1 2 No Low
and re-cycle to recover the products
resource depletion
Filtration of mass after from it
completion of reaction Provision is made for providing
Improper filtration /
Improper pressure on the effective pressure on plates and
29 loss of product / 1 3 1 3 No Low
plates during filtration mother liquor is collected from the
resource depletion
loss
Always right capacity pump is used
Less capacity of pump Less productivity /
and spare pump is kept in stock to
30 used to send mass to the resource depletion / 1 3 1 3 No Low
prevent the loss of product as well as
filter press loss of product
productivity

Format:E/SYS/02 Page 3 of 6
Doc. No. E/RA/01 Punyam Chemicals Limited
Issue No. 01
Date : 01-08-2014 Risk Analysis
Attributes Legal /
Sr. Magnitude Significance
Activity Aspect Risk Customer Present controls / Mitigation plan
No. A B C of Risks level
Concern
Always adequate equipments are
Spillages due to use of
Loss of product / used for material transfer. Also
31 improper equipments 1 3 1 3 No Low
resource depletion adeqaute equipments are kept in
during transfer
stock for its usage
Transfer of in process materials To use PPEs always. As well as
32 in the plant Contact with human Health hazards 1 3 5 15 Yes High contacts are made with the Hospitals
for emergenct treatment
Loss of product / Always right capacity equipments are
33 Material fall hazards 1 3 1 3 No Low
resource depletion used to prevent material fall hazards

Emergency stop switches are

Non-conforming
Increase in temperature provided to stop the heating as well
34 product generation / 2 4 5 40 Yes High
due to improper control as valves are provided to stop the
product burn hazards
steam / fuel supply to prevent supply.
Drying of product in the dryers Feeding system is controlled during
Improper inlet and outlet High moisture in
35 1 2 1 2 No Low operation to balance the inlet v/s.
during drying product
outlet
Spillage due to improper Loss of product / Adequate equipments are used
36 1 2 1 2 No Low
filling resource depletion during filling to prevent spillages etc.
Adequate equipments are used
Loss of product /
37 Spillage during charging 1 3 1 3 No Low during charging to prevent spillages
resource depletion
etc.
Stop the Mixer and open the charging
Increase in temperature Product burn / non- hole to release the heat and to dump
38 1 4 5 20 Yes High
during mixing conforming prodct the materials, in case of excess
heating
Materials are charged considering the
capacity of the mixer for effective
Blending of product in the Non-conforming
39 Improper mixing 1 4 1 4 No Low mixing of products. Periodic
blenders / ball mill / mixers etc. product generation
maintenance of mixing media such as
blades, balls etc.
Use of accurate weighing equipment
Re-process / to weigh the materials before
40 Improper charging 1 3 1 3 No Low
resource depletion charging to maintain the charging
ratio
 Blending of product in the
blenders
Doc. No. / ball mill / mixers etc.
E/RA/01 Punyam Chemicals Limited
Issue No. 01
Date : 01-08-2014 Risk Analysis
Attributes Legal /
Sr. Magnitude Significance
Activity Aspect Risk Customer Present controls / Mitigation plan
No. A B C of Risks level
Concern
To use PPEs always. As well as
41 Contact with human Health hazards 1 2 5 10 Yes High contacts are made with the Hospitals
for emergenct treatment

Format:E/SYS/02 Page 5 of 6
Doc. No. E/RA/01 Punyam Chemicals Limited
Issue No. 01
Date : 01-08-2014 Risk Analysis
Attributes Legal /
Sr. Magnitude Significance
Activity Aspect Risk Customer Present controls / Mitigation plan
No. A B C of Risks level
Concern
Spillages due to use of Adequate equipments are used
Loss of product /
42 improper equipments 1 2 1 2 No Low during charging to prevent spillages
resource depletion
during filling in packages etc.
To handle the packages with
43 Fall of packages Damages to property 1 2 1 2 No Low appropriate equipment to prevent fall
hazards
Shipping marks are verified with the
Packing of products in customer
customer order, before proceeding for
defined packages Customer
44 Improper shipping marks 1 4 5 20 Yes High pasting on it on the packages. Also
dissatisfaction
provision is made to print the shipping
marks immediately

All types of different packing materials

Re-filling / customer
45 Use of wrong packages 1 4 5 20 Yes High used in the Company are kept in
dissatisfaction
stock to prevent emergency situation
Proper stack height of packages are
46 Fall of packages Damages to property 1 2 1 2 No Low maintained to prevent its fall hazards
during storage
Product decompose due to Suitable environment is provided
Loss of product /
47 improper environment 1 5 1 5 No Low considering the nature of product to
resource depletion
Storage of packages at identified condition prevent its decomposition
area before its delivery
Stack height is controlled considering
Damages to packages due the strength of packages as well as
Loss of product /
48 to long storage / extra stack 1 4 1 4 No Low products are packed only when the
resource depletion
height same is ready for delivery against the
customer order requirements

Prepared By:

A Occurance (1 - 5)
B Severity (1 - 5)
C Legal / customer concern (1 / 5)
Magnitude of Risk : A*B*C
(*) Changes / addition made w.r.t. earlier issue