The Hierarchy of Risk Management: A Practical Guide for Safety Leaders

A forklift incident narrowly avoided at the warehouse. An overheated machine at the plant. These aren’t just stories—they’re signals. How we respond is guided by one simple yet powerful tool: the hierarchy of risk management.

When it comes to managing health and safety risks at work, there’s no one-size-fits-all fix—but there is a clear structure that helps you make smarter decisions. It’s called the hierarchy of risk management.

It doesn't matter if you're on a construction site, in a warehouse, or overseeing operations in a manufacturing plant—understanding how to prioritise control measures is key to keeping people safe and staying compliant.

This blog breaks down what the hierarchy is, why it matters, and how to use it to take the guesswork out of risk control—with practical examples that speak to the challenges safety leaders face on the ground.

What is the hierarchy of risk management?

The hierarchy of risk management is a system used to control hazards in the workplace by ranking safety measures from most effective to least effective. It helps businesses reduce risk by guiding decision-makers to focus on higher-level, longer-term solutions before relying on short-term fixes.

Also known as the hierarchy of controls, this model is commonly used across industries such as construction, manufacturing, and logistics to identify the best way to prevent harm. The five levels typically include: elimination, substitution, engineering controls, administrative controls, and personal protective equipment (PPE).

While you won’t always be able to use the highest-level option, the goal is to push as far up the hierarchy as is reasonably practical.

Why the hierarchy matters

The hierarchy exists for a reason (not all control measures have the same impact). Some only scratch the surface, while others actually deal with the hazard at its core.

Starting at the top means looking for ways to remove or replace the risk entirely. That’s where the biggest safety gains are made. Dropping straight to PPE or procedures might be quicker, but it often leaves the real issue in place.

This structure helps safety teams prioritise what works, especially when decisions need to be made fast or under pressure. It also lines up with legal requirements around what’s considered reasonably practicable, which is something every business needs to keep in mind when managing risks on site.

The five levels of hierarchy

1. Elimination

Elimination is about removing the hazard altogether. If there’s nothing to be exposed to, there’s nothing to control. It’s the most effective way to reduce risk because it cuts the problem off at the source.

This could mean redesigning a task so a dangerous step isn’t needed, swapping manual handling for automation, or scrapping a hazardous substance from a process entirely.

It won’t always be an option, especially in complex environments, but it should always be the first thing considered. Eliminating a risk means there’s no chance of it causing harm later.

2. Substitution

If you can’t remove the hazard completely, the next best thing is to replace it with something less dangerous. That’s what substitution is about - swapping out materials, equipment, or processes for safer alternatives.

Instances of this could include using a less toxic chemical, switching from a fuel-powered tool to an electric one, or replacing a noisy machine with a quieter model. The risk is still there, but it's reduced.

Substitution only works if the new option actually reduces harm, so it’s worth weighing up the trade-offs before making the switch.

3. Engineering controls

Engineering controls are physical changes to the workplace or equipment that help reduce exposure to a hazard. The goal is to isolate the risk or design it out of day-to-day tasks as much as possible.

This could include things such as machine guards, local exhaust ventilation, noise enclosures, or interlock systems that shut down equipment when someone gets too close. It can also mean redesigning layouts to keep people and hazards separated (like pedestrian walkways in a warehouse).

These controls are usually more reliable than admin processes or PPE, because they don’t rely on people doing the right thing every time.

4. Administrative controls

Administrative controls are the systems and processes put in place to manage how people work around a hazard. Instead of changing the hazard itself, these controls focus on reducing risk through training, procedures, scheduling, and communication.

Examples include lockout/tagout steps for equipment, rotating workers to limit exposure time, setting up safe work procedures, or using warning signs and checklists. They’re often used alongside other controls to strengthen safety measures.

Because they depend on people doing the right thing consistently, they’re considered less reliable than physical or design-based solutions.

5. Personal Protection Equipment (PPE)

[IMAGE & ALT TEXT: Australian road worker wearing high-visibility clothing, hard hat, and neck protection while holding a stop sign, demonstrating PPE in a roadside work zone.]

PPE is what workers wear to protect themselves when other controls aren’t enough. Again, it doesn’t get rid of the hazard, but it helps reduce the risk of injury or illness if something goes wrong.

This includes things like gloves, safety glasses, respirators, hard hats, and high-vis gear. It’s often used alongside other controls, especially when full elimination or isolation isn’t possible.

The catch is that PPE depends on people using it properly. If it’s not worn correctly, maintained, or replaced when needed, it won’t do its job. That’s why it should never be the only control you rely on.

Applying the hierarchy in practice

Putting the hierarchy into action starts with a few key steps: identify the hazard, assess the level of risk, and then work through the control levels from the top down. The goal is to always use the most effective control that’s practical for your situation (and combine methods where needed).

If you want a deeper look at how to manage each step, we cover the full process in our article How to Manage Work Health and Safety Risks.

Making the hierarchy work for you

The hierarchy of risk management gives you a clear way to prioritise safety decisions without relying on guesswork. By aiming higher up the hierarchy you’re putting stronger, longer-lasting controls in place that actually reduce risk.

To make it easier to apply these principles across your workplace, consider using a risk hazard management software that helps you track controls, manage actions, and stay compliant.

Ready to put the hierarchy into practice? myosh makes it easier to track controls, manage actions, and strengthen compliance—no guesswork required.  Start your free trial and see how safety management software can transform how your organisation handles risk.