HIRARC stands for Hazard Identification, Risk Assessment and Risk Control. In Malaysia, the DOSH HIRARC Guidelines (2008) provide a recognised methodology. The point is not to produce a large spreadsheet: it is to prevent harm by making work-related risks visible and controls effective.
Step 1: Define the activity precisely
A line reading “warehouse operation” is too broad. Break it into tasks such as forklift unloading, reversing into a storage bay, battery charging and pedestrian crossings. Include non-routine conditions such as maintenance, contractor activities and changes to the layout.
Step 2: Identify hazards and who may be harmed
Visit the work area and consult people doing the task. Consider moving vehicles, suspended loads, chemical exposure, noise, manual handling, falls and loss of energy control. Include visitors and contractors who may be exposed, not just direct employees.
Step 3: Assess the risk
Evaluate severity and likelihood using your organisation’s approved method and the DOSH guidance. A risk score can help prioritise; it should not replace professional judgement. Severe potential consequences may warrant stronger controls even when an event is considered unlikely.
Step 4: Select controls using the hierarchy
Prefer elimination, substitution and engineering controls where reasonably practicable before relying primarily on administrative controls and personal protective equipment. For forklift–pedestrian conflict, barriers and route separation are typically stronger than a warning poster alone.
Step 5: Assign ownership and verify
A usable HIRARC entry identifies the control, person accountable and verification method. “Stay alert” is difficult to audit. “Pedestrian gate stays closed while forklift loading is underway; supervisor checks before each loading shift” is observable and testable.
Worked example: forklift and pedestrian crossing
| Task | Hazard | Possible harm | Example control |
|---|---|---|---|
| Reverse forklift | Vehicle/pedestrian interface | Crush injury | Segregated route, barrier, designated crossing and visibility controls |
Document the initial risk using the approved matrix, implement controls, then reassess residual risk. Do not claim the task is safe solely because the numerical rating decreased; verify the actual arrangements at the worksite.
When should HIRARC be reviewed?
Revisit the assessment after incidents or near misses, new equipment, process changes, changes in workforce or site layout, or when controls prove ineffective. Regular planned review is also good practice. Involve the workforce and brief changed controls before the next task.
Common HIRARC errors
- Using the same generic risk register across dissimilar work areas.
- Describing injuries as hazards rather than identifying hazardous sources or situations.
- Listing PPE as the only control when higher-order controls are possible.
- Leaving action owners, verification and reassessment blank.
Is HIRARC legally required?
Section 18B of Act 514 requires risk assessment and implementation of necessary controls. It does not prescribe that every organisation must use a document titled “HIRARC” in all circumstances. DOSH’s HIRARC guidance offers one practical approach to meeting the risk assessment duty.
Want participants to complete a real task-based exercise rather than only learn definitions? View the HIRARC training programme or request a workplace-based workshop.
Official references
Example controls require validation against the actual worksite and approved risk assessment procedure.
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