Industry-specific OHS solutions
OHS services for automotive manufacturers and suppliers in Bursa
An OHS plan that assesses every station separately, from the press line and robotic welding cell to the paint shop and assembly, and manages health surveillance, periodic inspections and training in a single calendar.
- Hazard class
- Parts manufacturing (29.32.20) is hazardous
- Periodic medical examination
- At least every 3 years in hazardous class
- Basic OHS training
- 12 hours; job-specific risks in person
- Specialist certificate
- At least Class B for hazardous
Why does OHS in the automotive supply industry require dedicated expertise?
The automotive supply industry in Bursa consists of many plants in organized industrial zones (OIZs) such as Nilüfer OIZ, Bursa OIZ, Demirtaş OIZ and Hasanağa OIZ, producing parts, body components, wiring harnesses and sub-assemblies for vehicle manufacturers. In these plants, risks belong not to a single machine but to an interconnected production chain: work that starts on the sheet-metal press line passes through spot and MIG/MAG welding cells, surface treatment and the paint shop, and ends with assembly and shipping. Each station carries a different hazard, and as line speed increases, a small oversight can turn into a serious accident.
There is a common misconception about the hazard class: the entire supply industry is assumed to be very hazardous. In the list renewed on 13 March 2025 according to NACE Rev.2.1, the manufacture of parts and accessories for motor vehicles (29.32.20), body parts (29.32.21) and vehicle wiring harnesses (29.31.04) are in the hazardous class. However, if a very hazardous activity such as nickel plating is also carried out as a main activity at the site, the higher class applies. This distinction directly changes the required class of the specialist's certificate, the physician and specialist service times, training hours, examination intervals and whether other health personnel are required.
There is a second pressure in the supply chain: supplier audits by vehicle manufacturer customers. These audits examine in detail how up to date the risk assessment is, how effective the machine guards are, the chemical inventory and training records. Your OHS file needs to be as ready for a customer audit as it is for a Ministry inspection.
At Bursa Sistemer OSGB, we start in this sector with a line walk: we observe every station, die change, maintenance intervention and in-plant traffic on site; we score risks station by station and link each measure to a responsible person and a deadline. Health surveillance, periodic inspections, training and drill dates are tracked in a single annual plan.
The risks we encounter most often on site
Presses and die changes
Hand trapping and crushing on mechanical and hydraulic presses; the risk multiplies when light curtains, two-hand controls and safety blocks are bypassed. Lockout/tagout is essential during die changes and breakdown interventions.
Robotic welding and automation cells
Entering the robot working area through a fence gate or a bridged safety sensor is the source of the most severe accidents. Door interlocks, the emergency stop chain and reduced speed in teach mode are checked.
Welding fumes and metal dusts
Fumes and gases generated by MIG/MAG and spot welding affect the respiratory tract if there is no local exhaust at the welding point. Exposure becomes even more significant with stainless and coated sheet metal.
Paint booths and explosive atmospheres
Solvent vapor, powder coatings and two-component paints containing isocyanates carry both explosive atmosphere and respiratory sensitization risks. Zone classification, suitable equipment and ventilation checks are required.
Noise
In areas with presses, sheet cutting and pneumatic tools, noise often approaches the upper exposure action value. The measurement result determines the choice of hearing protection and the scope of hearing tests.
Assembly line ergonomics
Repetitive movements, reaching and lifting heavy parts in short-cycle assembly lead to shoulder, wrist and lower back disorders. Station-based ergonomic assessment and job rotation are planned.
Sample NACE codes and hazard classes
Your hazard class is determined by the NACE code in your Social Security Institution (SGK) registration. Examples of common codes in this industry:
| NACE | Activity | Hazard class |
|---|---|---|
| 29.32.20 | Parts and accessories for motor vehicles (gearboxes, brakes, shock absorbers, etc.) | Hazardous |
| 29.32.21 | Body parts | Hazardous |
| 29.31.04 | Wiring harnesses for vehicles | Hazardous |
| 29.10.02 | Manufacture of passenger cars | Hazardous |
| 25.51.01 | Nickel plating of metals (if carried out as a main activity at the site) | Very hazardous |
If your code is not listed, send it to us and we will confirm it against the current official list. Calculate the obligations for your class →
Health surveillance and medical testing plan
In a hazardous-class supplier plant, periodic medical examinations are carried out at least every 3 years; the physician may shorten this interval depending on exposure. Tests are determined station by station.
Pre-employment examination and fitness for work
In the hazardous class, an employee cannot start work without a fitness-for-work report. For press, welding and paint positions, the examination is carried out with the Annex 2 (EK-2) form according to the risks of the position.
Hearing tests
Hearing tests are mandatory in press and cutting areas where workplace measurements exceed the upper exposure action value of 85 dB(A); in areas above 80 dB(A) they may also be carried out at the physician’s discretion.
Lung function and chest imaging
Whether welders and painters need lung function tests, and how often, is the physician’s risk-based decision. For jobs with dust exposure, chest X-rays compliant with the ILO standard are taken; the physician determines their frequency.
Chemical-specific monitoring
Skin and respiratory sensitization is monitored in employees working with isocyanates, solvents and metalworking fluids. The physician plans biological monitoring and laboratory tests based on measurement results and safety data sheets.
Periodic inspections to keep track of
- Mechanical, hydraulic and eccentric presses: at least once a year
- Press brakes, guillotine shears, lathes and milling machines: at least once a year
- Overhead cranes, hoists and slings: once a year; proof load test at most every 3 years
- Forklifts and pallet trucks: at least once a year
- Conveyors and in-line handling systems: at least once a year
- Compressors and air receivers: once a year at operating pressure, at most every 3 years at test pressure
- Paint booth and welding exhaust systems (ventilation): at least once a year
- Internal electrical installation and earthing, generators and transformers: at least once a year
- Fire detection, sprinklers, hydrants and portable extinguishers: at least once a year
- Industrial racking and doors: at least once a year
Industry-specific training topics
- Lockout/tagout for presses and die changes
- Safe entry into robot cells and teach mode
- Fumes, radiation and burn risks in welding
- Explosive atmospheres and solvent safety in the paint shop
- Isocyanates and reading safety data sheets
- Noise and selecting hearing protection
- Forklift-pedestrian segregation and in-plant logistics
- Ergonomics and manual handling in assembly
How we apply our services in this industry
Documents you should have ready for an inspection
- Current risk assessment report (initialled, last page signed) and team appointment
- Specialist and physician contracts approved in İSG-KATİP (the Ministry’s OHS registration system)
- Annex 2 (EK-2) pre-employment and periodic examination forms, fitness-for-work reports
- Noise, dust and chemical workplace measurement reports (accredited laboratory)
- Periodic inspection reports for presses, cranes, forklifts, compressors and installations
- Induction, basic and refresher training records with exam results
- Vocational training certificates for positions in scope
- Emergency plan, list of emergency support teams and the latest drill form
- Chemical inventory and current safety data sheets
- Personal protective equipment (PPE) issue records
- Findings and recommendations logbook with evidence of closed actions
- Occupational accident and near-miss records, notifications to the Social Security Institution (SGK)
Areas where this industry is concentrated
Frequently asked questions
Is our automotive supplier plant in the very hazardous class?
Usually not. In the current list, parts and accessories (29.32.20), body parts (29.32.21) and wiring harnesses (29.31.04) are in the hazardous class. However, if a very hazardous activity such as nickel plating (25.51.01) or laser cutting (25.53.03) is also carried out as a main activity at your workplace, the higher class applies. We confirm your class from the NACE code in your SGK registration and show the result together with the obligations calculator.
Do robot cells need separate inspections?
Equipment inside the cell listed in Annex III, such as presses, lifting equipment or pressure vessels, is inspected according to its own maximum interval, at least once a year. In addition, safety functions such as door interlocks, light curtains, area scanners and the emergency stop chain must be tested regularly according to the manufacturer’s instructions and recorded. During visits, our specialist checks whether these tests are included in the maintenance plan and whether any safety devices have been bridged.
Which documents should be ready for our paint shop?
Because an explosive atmosphere can form in the paint shop, an explosion protection document must be prepared in addition to the risk assessment, zones must be classified and the suitability of electrical equipment used in these zones must be demonstrated. The ventilation system is inspected at least once a year. Safety data sheets for paints and thinners, solvent and isocyanate measurements and health surveillance records for painters must also be in the file. Booth filter replacement records are also frequently requested during inspections.
How do we prepare for our vehicle manufacturer customer’s OHS audit?
Customer audits usually include a detailed site inspection. The most frequently requested documents are the current risk assessment, photographic evidence of closed actions, machine guard checklists, the lockout/tagout procedure, the chemical inventory and the training matrix. Before the audit, we carry out a pre-assessment with our specialist, prioritize the gaps and compile the documents into a single file. If your customer has its own OHS specification, we match each clause against your current practice one by one.
How is training planned in a shift-based plant?
Under the new regulation published on 2 April 2026, basic OHS training can be split into sessions of at least 1 hour, which makes it easier to plan without stopping production. In the hazardous class, basic training is at least 12 class hours and the job-specific risks part (at least 3 hours) is delivered in person; the first three topics may be delivered remotely. Induction training of at least 2 hours for new starters is delivered in person and hands-on before they begin work.