Purpose of the Task

This task helps learners understand how risk-based systems become clearer when presented as step-by-step flows. When learners construct a process flow, the complex requirements of ISO 45001, strategic risk evaluation, and risk communication become easier to understand and apply in real workplaces. The task is directly linked to the three learning outcomes of the unit.

Scenario:

An organisation is updating its Permit-to-Work (PTW) system to meet ISO 45001 operational control requirements. The management team wants a clear process flow diagram that shows every stage from preparing a hazardous work activity to closing the permit after verification. The assessor provides the following scenario for the learner to interpret and convert into a structured process flow.

PART A — Scenario to be Converted into a Process Flow Diagram

• A maintenance team needs to carry out hot work inside a plant room.
• The supervisor must request a permit from the safety department.
• The job cannot begin until hazards are identified, risks are scored, and controls are agreed.
• The area must be inspected before work starts.
• Workers must be briefed on risks and control measures.
• Only trained workers may perform hot work.
• Monitoring must take place throughout the task.
• A fire watch must stay in place for 60 minutes after the work ends.
• The permit must be closed only after a final inspection confirms the area is safe.
• The completed permit must be stored for auditing and compliance.
• Learners must convert this narrative into a visual process flow.

PART B — Model-Completed Flow Diagram (Step-by-Step Representation)

Below is a fully completed model example of how the flow diagram should be structured. This is presented as text-based flow steps so the learner can understand the sequence clearly.

Model Process Flow: Permit-to-Work for Hot Work

1. Supervisor identifies the need for hot work.
2. Supervisor prepares a PTW request and submits it to the Safety Officer.
3. Safety Officer reviews the request and confirms if hot work classification applies.
4. Joint hazard identification is conducted with Supervisor and workers.
5. Quantified risk assessment is completed using the organisation’s scoring system.
6. Control measures are selected using the hierarchy of controls.
7. Pre-work area inspection is carried out to check housekeeping, flammables, access, and ventilation.
8. Safety Officer approves the permit once controls and inspection standards are met.
9. Supervisor briefs the workers through a toolbox talk before work starts.
10. Workers confirm competence (hot work training, equipment operation, PPE).
11. Hot work begins under active supervision.
12. Continuous monitoring by Supervisor and Safety Officer throughout the task.
13. Fire watch in place for a minimum of 60 minutes after the task ends.
14. Final area inspection to verify no ignition sources or smouldering materials remain.
15. Permit is formally closed by the Safety Officer.
16. Completed permit filed in the document control system for audit and ISO compliance.

PART C — How the Flow Supports the Unit Learning Outcomes

1. Development and implementation of ISO standards

The process flow aligns with ISO 45001 by showing:

clear planning stages
hazard identification
operational controls
competence requirements
monitoring and review
documented information control
formal approval and verification steps

This demonstrates how ISO procedures must be structured and consistently applied.

2. Evaluation of strategic risks through quantifiable systems

The flow shows exactly where risk scoring must occur.

• before work approval
• after hazard identification
• before selecting controls

This supports decision-making and ensures the assessment is strategic rather than reactive.

3. Communication of risk in various situations

The process identifies communication points:

• permit request
• hazard discussions
• toolbox briefing
• monitoring updates
• final verification

The sequence ensures every party understands the risk, the controls, and their responsibilities.

PART D — Learner Task Instructions

Learners must:

• Read the scenario provided in Part A.
• Build a process flow diagram with clear steps from start to finish.
• Ensure their flow diagram includes identifying hazards, scoring risks, obtaining approval, controlling the risk, monitoring the task, and closing the permit.
• Explain how each stage of their diagram supports ISO 45001 compliance, strategic risk evaluation, and clear communication.
• Compare their work to the model example to identify improvements.