Complete Guide to Filling Up a HIRARC Form in Malaysia

HIRARC (Hazard Identification, Risk Assessment and Risk Control) is a mandatory workplace safety process in Malaysia under the Occupational Safety and Health Act 1994 (Act 514).

This complete guide shows you exactly how to fill up a HIRARC form correctly, step by step, using official DOSH methodology, practical examples, and realistic workplace scenarios.

Whether you are a safety officer, supervisor, employer, or contractor, this guide will help you:

• Comply with Malaysian legal requirements
• Produce audit-ready HIRARC documentation
• Reduce workplace accidents and long-term health risks

What Is HIRARC?

HIRARC stands for:

• Hazard Identification – identifying anything that can cause harm
• Risk Assessment – evaluating likelihood and severity of harm
• Risk Control – implementing measures to eliminate or reduce risk

It is a systematic and documented approach used to protect workers’ safety and health.

Legal Requirement in Malaysia

Under OSHA 1994, employers must:

• Conduct HIRARC for all work activities
• Document findings and control measures
• Implement controls based on risk priority
• Review HIRARC at least every 3 years or when changes occur

Failure to do so may result in DOSH enforcement action, including fines or work stoppage.

Part 1: Understanding the HIRARC Form Structure

A standard HIRARC form contains:

1) Header Section

• Company Name
• Process / Location
• Conducted By (HIRARC team)
• Date Conducted
• Approved By
• Review Date

2) Main Table (Core Assessment)

• No.
• Work Activity
• Hazard
• What can cause / effect
• Existing Risk Control
• Likelihood (L)
• Severity (S)
• Risk Level
• Recommended Control Measures
• PIC
• Status

Each row represents one activity + one hazard.

‍

Part 2: Filling Up the Header Section Correctly

Company Name

Use the full registered company name
Example: ABC Manufacturing Sdn Bhd

‍

Process / Location

Be specific but practical.

Good examples

• Wood Cutting Section – Factory Floor 2
• Plastering Work – Exterior Wall
• Chemical Storage Area

Bad examples

• Entire factory (too broad)
• Ahmad’s workstation (too narrow)

‍

Conducted By (HIRARC Team)

Must include:

• Management / supervisor
• Workers performing the job
• Safety officer (if available)

Workers must be involved — they understand real risks better than anyone.

‍

Date & Review Date

• Record start and end dates
• Review every 3 years, or immediately after:
  • Process change
  • New machinery
  • Accident or near-miss

‍

Part 3: Filling Up the Main HIRARC Table (Column by Column)

COLUMN 1: No.

Simple numbering: 1, 2, 3…

COLUMN 2: Work Activity

Break work into logical steps (4–10 steps per process).

Example – Wood Cutting

1. Loading wood panels onto machine
2. Operating cutting machine
3. Unloading cut panels
4. Machine maintenance

Avoid

• “General factory work”
• Overly detailed micro-steps

COLUMN 3: Hazard

Identify what can cause harm.

Common hazard categories in Malaysia:

• Physical (falls, noise, heat)
• Mechanical (moving parts, blades)
• Chemical (fumes, solvents)
• Ergonomic (heavy lifting, posture)
• Electrical (exposed wiring)
• Biological (mould, bacteria)

Example

• Exposed cutting blade
• Unguarded floor edge
• Noise > 85dB

COLUMN 4: Which Can Cause / Effect

State the realistic consequence.

Format:

Injury type / Severity

Examples

• Hand caught in rotating parts / amputation
• Slip and fall / fracture
• Noise exposure / permanent hearing loss

COLUMN 5: Existing Risk Control

List controls already in place — be honest.

Types:

• Engineering (guards, barriers)
• Administrative (SOP, training)
• PPE (gloves, goggles)

If none exist, write “Nil”.

Do not list planned controls here.

‍

Part 4: Risk Assessment (Likelihood × Severity)

Likelihood (L)

How often could this happen?

Severity (S)

How bad would it be?

Risk Calculation

Risk = L × S

What the Risk Level Means

• HIGH → Stop work, act immediately
• MEDIUM → Plan and implement controls
• LOW → Acceptable, monitor and improve

Part 5: COLUMN 7: Recommended Control Measures

Controls must follow the Hierarchy of Control (most effective → least effective):

1) Elimination

Remove the hazard entirely

2) Substitution

Replace with safer alternative

3) Engineering Controls

Guards, barriers, ventilation, automation

4) Administrative Controls

SOPs, training, permits, inspections

5) PPE (Last Line of Defence)

Gloves, helmets, goggles, harnesses

PPE alone is never sufficient.

‍

Part 6: COLUMN 8: Person In Charge (PIC) & Timeline

Format:

Name (Due Date) / Status

Status examples:

• Completed
• In Progress
• KIV (with reason)
• Overdue

Assign responsibility to someone with authority.

Part 7: Complete HIRARC Examples

✔ Wood Cutting Process
✔ Exterior Wall Plastering Work

‍

Part 8: Common Mistakes to Avoid

• Activities too generic
• Hazards described vaguely
• Unrealistic risk ratings
• Relying only on PPE
• No worker involvement
• No follow-up or review

These are red flags during DOSH inspections.

‍

Part 9: Final Checklist Before Submission

✔ Header complete and approved
✔ Activities logical and accurate
✔ Hazards specific and observed
✔ Risk ratings realistic
✔ Controls follow hierarchy
✔ PIC and dates assigned

Part 10: Frequently Asked Questions (FAQ)

How often must HIRARC be done?
Minimum every 3 years, or when changes occur.

Who should conduct HIRARC?
Management + workers + safety personnel.

Is HIRARC submitted to DOSH?
Not routinely, but must be available on request.

Can we modify the format?
Yes as long as all core elements are present.

Conclusion

HIRARC is not just a form, it is a way of thinking about safety.

When done properly:

• Accidents reduce
• Compliance improves
• Productivity increases
• Workers go home safe

The best HIRARC is done with workers, on the ground, honestly and continuously.

‍

Disclaimer

This guide is based on the Guidelines for Hazard Identification, Risk Assessment and Risk Control (HIRARC) 2008 issued by the Department of Occupational Safety and Health (DOSH), Malaysia. It is for educational purposes and does not replace professional or regulatory advice.

‍

Download a copy of the 2008 HIRARC Guide from the Department of Occupational Safety and Health (DOSH) Malaysia here!