1) HSE Policy Statement (for CEO signature)

GAUCACH LIMITED is committed to Zero Harm to people, assets, and the environment. We will conduct all operations—LPG product distribution, hygiene manufacturing, and training delivery—safely, responsibly, and in full compliance with applicable laws and standards.
We will:

• Put safety first in every decision.

• Identify and control hazards using risk‑based thinking.

• Prevent pollution and minimize waste in all activities.

• Provide the training, equipment, and supervision necessary for safe work.

• Consult and involve employees, contractors, and stakeholders in HSE matters.

• Measure performance and continually improve.

Signed: Managing Director/CEO, GAUCACH LIMITED
Date: __________________

2) HSE Objectives & Targets (Annual)

• Zero fatalities & life‑altering injuries; TRIR ≤ 0.25 for field/warehouse operations.

• 100% legal compliance (permits, NAFDAC/SonCAP where applicable).

• 100% workforce HSE induction & role‑based training; refreshers ≥ 2x/year.

• >95% closure of HSE corrective actions within 30 days.

• ≥90% emergency drill participation; evacuation time ≤ 3 minutes for sites.

• Waste reduction ≥ 15% YoY in manufacturing; 100% proper disposal records.

• Zero Significant Spill/Fire incidents; >98% gas‑leak detection compliance during inspections.

3) Scope & Applicability

• Sites: Offices, showrooms, retail points, warehouses, workshops, manufacturing lines, training centers, and logistics.

• People: Employees, contract staff, trainees, visitors, and third‑party logistics.

• Activities: LPG equipment storage/handling, soap production, distribution, training delivery, maintenance, and administration.

4) Roles & Responsibilities (RACI Snapshot)

Role

Key HSE Duties

CEO/MD

Approves HSE policy, sets objectives, provides resources, chairs quarterly HSE review.

HSE Manager

Develops procedures, leads risk assessments, audits, incident investigations, training matrix, regulatory liaison.

Operations/Plant Lead

Implements SOPs, ensures permits, supervises housekeeping, ensures inspections and tool availability.

Warehouse/Store Lead

Cylinder segregation, compatibility, ventilation, stacking limits, leak tests, MSDS availability.

Training Lead

Designs HSE courses, conducts drills, maintains competence records & certifications.

Supervisors

Daily toolbox talks, PTW control, field observations, immediate corrective actions.

All Staff/Contractors

Follow rules, use PPE, stop work if unsafe (Stop‑Work Authority), report hazards & near misses.

5) Risk Management

5.1 Hazard Identification & Risk Assessment (HIRA)

• Use a 5x5 risk matrix (Likelihood × Consequence).

• Conduct baseline, task‑based JSA, and change‑of‑process risk reviews.

• Record controls using the Hierarchy of Controls (Elimination → Substitution → Engineering → Administrative → PPE).

Top LPG‑Related Risks & Controls (examples):

• Gas leaks/flash fire: intrinsically safe detectors, leak‑test (soapy water), approved regulators/hoses, ventilation, no‑smoking zones, antistatic flooring, ignition‑source control, hot‑work PTW, emergency shut‑offs.

• Cylinder handling injuries: trolleys, team lifts, ramps, gloves, footwear, manual handling training.

• Storage explosion risk: segregation by fill level, upright storage with caps, max stacking height, separation distances, barricades, signage.

Manufacturing (Soap) Risks & Controls:

• Caustic burns (NaOH): chemical‑proof PPE (goggles/face shield, gloves, apron), eyewash stations, MSDS, dosing controls.

• Mixing/heating hazards: guarding, interlocks, temperature alarms, LOTO during maintenance.

• Slips/trips: floor grading, anti‑slip mats, housekeeping, spill kits.

Training Venue Risks & Controls:

• Crowd & egress: occupancy limits, clear exits, muster points, PA system.

• Practical demos: pre‑use checks, instructor‑to‑trainee ratio, first‑aid presence.

6) Key Procedures (SOPs)

1. Permit‑to‑Work (PTW): Hot‑work, confined space, electrical isolation (LOTO), work at height.

2. LPG Receiving & Storage: Acceptance checklist, cylinder integrity, pressure checks, segregation, ventilation, signage.

3. LPG Retail Handling: Leak checks, regulator fitting, hose replacement intervals, customer safety advisory at point of sale.

4. Chemical Handling (Soap): MSDS, decanting/labeling, compatible storage, spill response.

5. Contractor Management: Prequalification, HSE induction, method statement/JSA approval, supervision.

6. Driving & Fleet Safety: Defensive driving, journey management, vehicle inspection (pre‑trip), speed policy, loading/strapping.

7. Housekeeping & Waste: 5S standards, segregation, hazardous waste vendor approvals, records retention.

8. LOTO (Lock‑Out/Tag‑Out): Energy isolation steps, verification tests, removal rules.

9. Incident Reporting & Investigation: Immediate notification, secure scene, root‑cause (5‑Why, RCA), corrective/preventive actions (CAPA), lessons learned.

10. Emergency Response: Alarm types, evacuation routes, muster points, fire classes, extinguisher use (PASS), roles (Warden, First Aider), post‑incident debrief.

7) Emergency Preparedness & Response (EPR)

• Scenario Plans: LPG leak/fire, chemical splash, electrical fire, spill, medical emergency.

• Equipment: ABC/CO₂ extinguishers, sand buckets, spill kits, first‑aid boxes, eyewash/shower, gas detectors.

• Drills: Quarterly evacuation; biannual LPG leak scenario; annual multi‑agency drill (fire service, landlord, neighbors where applicable).

• Muster: Marked assembly points, headcount within 3 minutes.

• Post‑drill: Report within 24 hours; corrective actions ≤ 30 days.

8) Training & Competence Matrix (extract)

Role

Induction

LPG Handling

Chemical Handling

PTW

Fire Warden

First Aid

Defensive Driving

All Staff

✔ Onboarding + annual

Awareness

Awareness

–

–

–

–

Warehouse/Shop

✔

✔ Practical

–

–

–

–

–

Plant Operators

✔

–

✔ Practical

✔

–

–

–

Supervisors

✔

✔

✔

✔ (issuer/receiver)

–

–

–

Wardens

✔

–

–

–

✔

–

–

First Aiders

✔

–

–

–

–

✔

–

Drivers

✔

–

–

–

–

–

✔

Refreshers: every 12 months (or sooner after incidents/changes).

9) HSE KPIs & Monitoring

• Lagging: TRIR, LTIs, first‑aid cases, spills, fires, near‑misses (target: +50% near‑miss reporting YoY to build reporting culture).

• Leading: % completed inductions, % closed actions on time, inspections/month, toolbox talks/week, PTW audits, vehicle inspections, drill performance.

• Inspections/Audits: Weekly supervisor inspections; monthly HSE audit; quarterly management walk‑downs.

• Review: Quarterly HSE performance review chaired by MD.

10) Document & Record Control

• Policies/SOPs: versioned, approved, and accessible.

• Records: training, inspections, PTW, incidents, maintenance logs, waste manifests, MSDS—retention ≥ 3–5 years.

• Change Management: review HSE risks before new products/processes/sites.

11) PPE Standards (minimum)

• Warehouse/LPG areas: safety shoes, gloves, flame‑resistant coveralls, eye protection; hearing protection as needed.

• Soap plant: chemical‑resistant gloves, goggles/face shield, apron, closed footwear.

• Drivers: high‑viz vest, safety shoes during loading/unloading.

• Visitors: escorted, briefed, and issued appropriate PPE.

12) Contractor & Supplier HSE

• Pre‑qualification (HSE policy, incidents, certifications).

• Site induction + JSA approval.

• Permit control and supervision.

• Post‑job evaluation and lessons learned.

13) Community & Environmental Management

• LPG awareness for nearby businesses/residents where relevant.

• Noise, dust, and traffic minimization measures.

• Waste hierarchy (reduce, reuse, recycle) and licensed disposal.

• Spill prevention; secondary containment for chemicals.

• Energy/water use tracking with reduction targets.

14) 90‑Day Implementation Plan (practical)

Days 0–30

• Issue signed HSE Policy.

• Appoint HSE Manager and site wardens/first aiders.

• Complete baseline HIRA & emergency plan.

• Mandatory induction for all staff/contractors.

• Procure critical emergency equipment (extinguishers, spill kits, eyewash).

Days 31–60

• Roll out SOPs (PTW, LOTO, LPG handling, chemical handling).

• Conduct first evacuation drill; close actions.

• Start leading KPI dashboards and weekly inspections.

• Vendor checks (LPG/chemical suppliers) with HSE criteria.

Days 61–90

• Conduct PTW & LOTO audits, vehicle inspections program.

• Supervisor coaching on toolbox talks & field observations.

• Management quarterly HSE review; set next‑quarter targets.

• Publish “Lessons Learned” bulletin from first 2 months.

15) Quick‑Use Templates (you can copy/paste)

a) Toolbox Talk (daily/shift)

Date/Location:

Topic:

Hazards Discussed:

Controls/PPE:

Questions/Feedback:

Supervisor:

Attendees/Signatures:

b) Incident/Near‑Miss Report (short form)

Date/Time:

Location:

Persons Involved:

Description:

Immediate Cause:

Underlying Cause:

Initial Action Taken:

Corrective/Preventive Actions (owner/date):

Reported by: