File 04: Identifying product hazards
The hazards that turn up in consumer products, how to spot them, and how to record them before they become incidents.
The file guide
Working guides in this file
04A Field Guide to Hazard Types in Consumer Products Hazard types in consumer products span mechanical, electrical, chemical, thermal, and strangulation risks, and naming the type correctly helps a seller choose the right check for each one. 04Batteries Under Pressure: Hazards from Batteries and Charging Hazards from batteries and charging include overheating, swelling, leakage, and fire, especially when chargers mismatch, batteries are damaged, or charging happens on soft bedding. 04Cords, Strings, and Magnets: Three Small Hazards That Combine Hazards from cords, strings, and small magnets combine in products where a loop can catch, a string can wrap, or a magnet can detach and be swallowed, each needing its own length, strength, or enclosure check. 04Current Where It Should Not Be: Electrical Hazards Explained Electrical hazards arise from faulty insulation, exposed conductors, overload, or water contact, so prevention centres on intact cables, correct fuses, and keeping electricity away from water. 04Edges That Cut: Sharp Edges and Points in Products Hazards from sharp edges and points arise where metal, glass, or plastic edges can cut or puncture skin during normal handling, assembly, or cleaning, so edge finishing and burr checks are central. 04Hidden Allergens: When a Product Triggers a Reaction Hazards from allergens in products arise when an ingredient or material triggers an allergic reaction in a sensitive user, so clear ingredient lists and honest material disclosure are the main defences. 04Hot Surfaces and Open Flames: Burns and Fire Hazards at Home Burns and fire hazards arise when heat, flame, or hot surfaces meet skin, fabric, or nearby materials, so prevention focuses on surface temperatures, flame spread, and keeping ignition sources away from fuel. 04Invisible Ingredients: Chemical Hazards in Everyday Products Chemical hazards in consumer products come from ingredients that irritate, sensitise, or harm through skin contact, inhalation, or swallowing, so labelling, ventilation, and proper storage matter as much as the product itself. 04Loops That Catch: Strangulation and Entanglement Hazards Strangulation and entanglement hazards arise when loops, cords, or loose fabric can wrap around a neck or limb, especially for sleeping children and pets who cannot free themselves quickly. 04Moving Parts That Bite: Mechanical Hazards Explained Mechanical hazards come from moving parts, crushing points, springs, and unstable structures that can trap, pinch, or strike a user during normal use or assembly. 04Rain, Sun, and Rough Ground: Hazards in Outdoor Products Hazards in products used outdoors grow with weather, sunlight, uneven ground, and long exposure, so materials, stability, and weather resistance need checks that indoor products never face. 04Tiny Parts, Big Danger: Choking and Small Parts Hazards Choking and small parts hazards occur when a detachable or breakable part fits a small airway, so the check focuses on part size, attachment strength, and how a child might break or bite a product apart. 04Together They Change: Hazards When Products Are Used Together Hazards when products are used together appear only in combination, such as a mat that slips on a polished floor, a charger that overheats a case, or a cleaning product that reacts with another surface. 04Too Loud, Too Long: Hazards from Noise and Vibration Hazards from noise and vibration come from sound levels and shaking that damage hearing or strain hands and arms over time, so duration, distance, and protective habits matter alongside the product itself. 04Too Many Hazards, Too Little Time: How to Prioritise Hazard prioritisation when many hazards compete means ranking by severity of harm and likelihood for real users first, then tackling the highest combination before polishing lower risks. 04Used the Wrong Way, Predictably: Hazards from Misuse Hazards from misuse and foreseeable use arise when people use a product in a way the maker should have anticipated, even if instructions say otherwise, so warnings must address likely behaviour, not only correct behaviour. 04When Software Changes the Product: Connected Product Hazards Hazards in connected and software products shift after sale, because updates, connectivity loss, and app changes can alter how a device behaves long after it leaves the shop. 04When Users Cannot Protect Themselves: Hazards for Vulnerable Users Hazards for vulnerable users matter most where the user cannot read a warning, judge a risk, or react quickly, including young children, older people, and people with limited strength or mobility. 04Write It Down or Lose It: Recording Hazards Properly Recording hazards so they are not lost means writing each hazard, its product, its user, and its evidence in a place the team can find later, rather than trusting memory or a passing conversation.