Free Manufacturing Risk Assessment Tool for WHS

Identify common risks, compliance gaps, potential hazards, and operational risks across your manufacturing facility with a fast, free WHS assessment.
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WHS risk level
Answer 7 quick questions to see your actual score.

How to complete the WHS assesment

1. Answer 7 quick questions

Tell us how you manage visitors, contractors, inductions, emergency processes, process requirements relevant to safety and compliance, and other critical operations.

2. Get your WHS risk score instantly

We assess your responses and show your current risk level with a real-time gauge.

3. Receive a full PDF report by email

Your emailed report includes a breakdown of potential risks, identification of any particular hazard that may require special attention, recommended risk control measures, and practical steps to strengthen safety and compliance across your site.

Running a manufacturing site means dealing with contractors coming and going, maintenance teams, auditors, delivery drivers and visitors. With so many people entering operational areas, even small gaps in your sign-in, induction or emergency processes can create real WHS exposure. This assessment helps you quickly benchmark your current approach and spot risks you may not have noticed.

Once you receive your personalised PDF report, you’ll get a clearer picture of where improvements can be made. You’ll also see how a digital visitor and contractor management system like VisitUs can help streamline sign-ins, automate inductions, verify contractor credentials and give you real-time visibility of who is on site. All critical elements for a safer, more compliant manufacturing environment.

Who is the assesment for?

WHS managers responsible for visitors and contractors

Ensures your current sign-in, induction and compliance processes are meeting WHS obligations.

Operations / plant managers who need better headcounts in emergencies

Helps identify gaps in real-time visibility so you can account for everyone on site during critical events.

HSE or compliance teams preparing for audits

Provides clear evidence of process risks and where digital improvements can strengthen audit readiness.

Best Practices for Risk Assessment

To maximise the effectiveness of risk assessment in manufacturing, it’s important to follow industry best practices. This includes conducting regular and systematic evaluations, utilising specific tools such as fault tree analysis and failure modes and effects analysis (FMEA) to identify potential hazards and possible failures.

Involving workers in the assessment process ensures a comprehensive understanding of risks at every level. Manufacturers should prioritise hazards based on their likelihood and potential impact, implementing control measures to address the most critical risks first. Regularly reviewing and updating risk assessments is essential, as new risks can emerge and existing controls may need adjustment.

By adopting a structured process and allocating resources strategically, manufacturers can ensure their risk management efforts remain effective and responsive to changing operational needs.

Start your WHS risk assessment

How do visitors and contractors sign in today?
Roughly how many visitors and contractors arrive per week?
Do you verify contractor licences or IDs before they start work?
How do you complete safety inductions for visitors and contractors?
How do you perform headcounts during an evacuation or emergency?
Can you see who is on site right now, including visitors and contractors?
Do visitors and contractors sign out when they leave?
Please answer all questions to continue.
Please enter a valid work email address.
Your WHS risk assessment
Risk level
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What your WHS risk assessment reveals

Manufacturing companies face a unique mix of operational risks — from supply chain disruptions to equipment failure, hazardous materials, inventory management issues, compliance gaps, and natural disasters.

This assessment highlights the key areas where your processes may be failing, including:

 

  • Incomplete contractor verification
  • Lack of induction consistency
  • Limited visibility of who is on site
  • Manual emergency response workflows
  • Ineffective control measures
  • Potential failures in critical processes

 

The assessment provides actionable insights to help you manage risks more effectively across your manufacturing operations.

How accurate is the WHS risk score?

The score is based on key WHS risk factors common in manufacturing, including sign-in methods, induction processes, contractor verification and emergency visibility.

 

While it doesn’t replace a full WHS audit, it gives a reliable snapshot of your current exposure and highlights where improvements will have the greatest impact.

Does the assessment cover contractors as well as visitors?

Yes. The tool specifically evaluates how your site manages contractors including licences, IDs, inductions and sign-outs.

 

It’s covered in the assesment because contractor processes are one of the most common WHS gaps in manufacturing environments.

Why do I need to enter my email to get the results?

Your full WHS report is generated as a personalised PDF that includes your answers, risk level and recommended improvements.

 

We email it so you can share it with WHS, ops or compliance teams. We never send spam, and your email is not shared with any third parties.

How can VisitUs help reduce WHS risk on a manufacturing site?

VisitUs replaces manual or inconsistent processes with a digital workflow that includes induction management, visitor and contractor sign-ins, licence checks, notifications and real-time presence reporting.

 

This helps reduce emergency response time, improves audit readiness and ensures you know exactly who is on site at all times.

Introduction to Manufacturing Risk Assessment

Manufacturing risk assessment is a structured process designed to identify, evaluate, and control potential risks within the manufacturing industry.

By systematically examining operations, manufacturers can uncover potential hazards before they escalate into workplace incidents. This proactive approach to risk management not only helps address emerging risks but also ensures compliance with regulatory requirements and industry standards. Regular risk assessments are essential for maintaining operational performance, as they enable manufacturers to prioritize resources, implement effective controls, and continuously improve safety protocols.

Ultimately, a robust risk assessment program is a key enabler of operational excellence, empowering manufacturing companies to stay ahead of risks and safeguard both their workforce and business continuity.

Why the Manufacturing Industry Needs a WHS Risk Assessment

Running a manufacturing operation means constant movement of contractors, auditors, delivery drivers, visitors and maintenance teams. With so many people entering operational areas, even small gaps in your safety protocols can create real exposure.

A structured risk assessment helps you:

  • Identify potential hazards early
  • Address risks before workplace incidents occur
  • Improve operational performance and emergency readiness
  • Strengthen compliance with regulatory requirements
  • Allocate resources more effectively
  • Stay ahead of emerging risks in a complex manufacturing environment
  • Identify external factors that could impact manufacturing operations, such as opportunities and threats outside the organization

 

Once you receive your personalised PDF report, you’ll also see how a digital visitor and contractor management system like VisitUs reduces manual work, improves visibility and enhances WHS compliance.

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Real time visibility

Get a live, accurate list of everyone on site including contractors, visitor, drivers and maintenance teams. This assists in faster emergency response times and a safer workplace.

Instant notifications

Automatically notify supervisors, hosts or safety teams when someone arrives, or when an emergency is in progress.

Automated inductions & compliance checks

Ensure every visitor and contractor completes the correct safety induction and provides required IDs or licences before entering your production areas.

iPad, Android and QR code

Deploy VisitUs on kiosks, rugged tablets or simple QR codes. Ideal for manufacturing sites with multiple entry points or varying shift patterns.

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