2356 Table 1 - Examples of design variants and observed frontline effects Design choice (variant) Typical rationale Observed effect at the frontline Single, enterprise-wide risk matrix vs. multiple matrices (enterprise/corporate/site) Comparability vs. technical nuance A single matrix can strengthen consistency, improve understanding of escalation thresholds, and provide clarity on what constitutes “high” or “critical.” Multiple matrices can support technical specificity where needed, but when poorly reconciled they create confusion as thresholds and colour conventions diverge. This leads to inconsistent escalation decisions, uncertainty about required controls, and disagreement over risk priority. Health integrated with safety vs. separate health framework Unified reporting vs. specialist focus When integrated well, frontline personnel receive a unified picture of exposure and injury risks, making pre-start discussions more coherent. When health is separate but clearly linked, specialist knowledge is preserved and controls can be more targeted. However, if separation is poorly linked, exposure controls and monitoring results do not reliably reach supervisors, health-related learnings move slowly across boundaries, and workers may miss critical information about noise, dust, vibration, or psychosocial risks relevant to today’s tasks. Critical controls stored in safety tool vs. operational planning vs. ORM Ownership clarity vs. system constraints When critical controls have a clearly defined single source of truth frontline leaders gain confidence in verification requirements, and evidence can be traced through planning, execution, and governance cycles. When controls are distributed across tools without alignment, verification evidence becomes fragmented or duplicated, making it difficult to confirm whether controls are in place. This reduces confidence, delays decisions, and complicates conversations about control effectiveness. Document-centric assurance vs. control-effectiveness assurance Ease of auditing vs. operational realism Control-effectiveness assurance helps supervisors and crews understand whether controls actually work under current conditions, strengthening trust and decision-making. A document-centric approach can shift conversations toward completing forms rather than confirming the functionality of controls, weakening the link between system intent and operational practice. 9. LIMITATIONS The paper reports practice-based, qualitative insights rather than a single controlled study. Sites differ in technology, regulation, and workforce composition. Nevertheless, the patterns appear consistently across multiple cohorts, companies, and contexts. Examples have been generalised and anonymised to protect confidentiality while preserving learning value.
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