Master Knowledge Application Task (KAT) Training

ProQual Level 7: Knowledge Application Task (KAT) Training

Purpose

This Knowledge Application Task places the learner in a realistic organisational environment where a serious safety concern has emerged. The learner must apply advanced strategic safety leadership skills to review hazards, collect evidence, conduct root cause analysis, and design a corrective-action plan grounded in ISO 45001, UK legislation, and risk-based safety principles.
The scenario also requires strategic risk thinking and strong communication planning.

Scenario Overview

A large UK-based civil engineering company is carrying out multi-storey refurbishment works. During routine internal monitoring, senior management has observed an increase in near-miss reports involving suspended loads, damaged access equipment, and poor waste-handling practices. One incident involved a worker stepping onto a defective platform ladder, which shifted and caused the worker to lose balance. No injury was recorded, but the event showed several control failures.

An internal audit flagged weaknesses in:

  • Permit-to-work controls
  • Site inspection systems
  • Contractor coordination
  • Communication of critical risks
  • Waste handling and housekeeping

The Managing Director requires a full safety investigation and strategic corrective plan.

Learners must now respond as competent senior H&S practitioners.

TASK REQUIREMENTS

Part 1 – Hazard Identification and Documentation (Aligned to ISO 45001:2018 Clause 6.1)

The learner must prepare a structured hazard-identification record covering three critical areas:

  1. Access equipment and work-at-height hazards (ladders, MEWPs, platforms)
  2. Suspended load movement during lifting operations
  3. Housekeeping and waste-handling failures

Each hazard entry must contain:

  • Hazard description
  • Persons at risk
  • Existing controls
  • Failure of controls
  • Legal duties breached
  • ISO 45001 clauses triggered
  • Severity and likelihood scoring using a quantified UK-compliant risk matrix

Key UK legislation to be referred to:

  • Health and Safety at Work etc. Act 1974
  • Management of Health and Safety at Work Regulations 1999
  • Work at Height Regulations 2005
  • Provision and Use of Work Equipment Regulations 1998 (PUWER)
  • Lifting Operations and Lifting Equipment Regulations 1998 (LOLER)
  • Waste (England and Wales) Regulations 2011

The documentation must show how the learner applied a strategic, systematic riskassessment approach suitable for a Level 7 competency standard.

Part 2 – Root Cause Analysis (RCA)

The learner must conduct a professional root cause analysis, using one of the following:

  • 5 Why Technique
  • Fishbone (Ishikawa) diagram
  • Fault Tree Analysis (FTA)

The RCA must identify:

  • Immediate causes (unsafe acts, defective equipment, poor behaviours)
  • Underlying causes (poor supervision, weak inspection regimes, unclear roles)
  • Root organisational causes (strategic gaps, resourcing issues, weak governance, poor leadership)

Reference must be made to:

  • ISO 45001:2018 Clause 10.2 (Incident Investigation and Corrective Action)
  • UK HSE guidance HSG245 “Investigating accidents and incidents”

The RCA must demonstrate how organisational failures allowed repeated near misses to occur.

Part 3 – Corrective and Preventative Action Plan (CAPA)

Learners prepare a strategic improvement plan that includes:

1: Engineering controls

  • Replacement of defective equipment
  • Improved mechanical lifting devices
  • Separated walkways

2: Administrative controls

  • Revised permit systems
  • Strengthened contractor coordination
  • Enhanced monitoring and inspection processes

3: Training and competency

  • ISO 45001-aligned competency framework
  • Mandatory briefings on ladder safety, housekeeping, lifting operations

4: Leadership and governance measures

  • Senior leadership oversight meetings
  • Key performance indicators (KPIs) for compliance
  • Internal auditing schedule improvements

The CAPA must link each action to relevant:

  • UK legal requirements
  • ISO 45001 clauses
  • Strategic organisational objectives & Quantified residual risk scores

Part 4 – Strategic Risk Evaluation (Learning Outcome: Evaluate strategic risks)

The learner must prepare a short analytical report showing:

  • How repeated near misses indicate systemic risk
  • How poor control of high-risk activities (working at height, lifting) threatens business continuity, reputation, and regulatory compliance
  • How a quantifiable risk assessment model guides executive decision-making
  • The organisational impact of failing to meet ISO 45001 requirements

The evaluation must show a strategic understanding, reflecting Level 7 depth.

Part 5 – Risk Communication Strategy (Learning Outcome: Articulate risk communication strategies)

Learners design a communication plan that explains how safety information will be shared with:

  • Frontline workers
  • Subcontractors
  • Supervisors
  • Senior management
  • External stakeholders (if required)

The plan must:

  • Use clear, structured language that enables understanding at all levels
  • Include visual aids (simple charts, traffic-light risk indicators)
  • Define communication responsibilities
  • Support compliance with ISO 45001 Clause 7.4 (Communication)

A brief example may be included, such as a sample communication message for workers.

Guidance for Learners

Learners must submit:

  1. Hazard identification table (completed in detail)
  2. Full RCA with diagrams or structured reasoning
  3. Comprehensive CAPA plan
  4. Strategic risk evaluation report (500–800 words)
  5. Risk-communication plan (structured format)
    All content must reflect high-level professional reasoning suitable for ProQual Level 7.