How can changes in processes lead to new hazards?

Changes in processes can introduce new hazards primarily because altering existing procedures might involve the use of unfamiliar materials or methods that have not been adequately assessed for associated risks. When a process is updated or modified, it is common for new variables to be introduced, such as different chemicals, equipment, or operational techniques. These new elements may react differently than the previous ones, potentially leading to unexpected hazards.

For instance, introducing a new chemical into a reaction might create toxic by-products or increase the potential for fire or explosion. Moreover, if workers are not familiar with the new processes or materials, they may not recognize the safety precautions needed, further increasing the risk of incidents.

While it is ideal for changes in processes to be thoroughly examined for safety, in practice, not all changes can be anticipated or fully tested before implementation. This is why proper hazard assessment and training are essential when modifying processes.