The hierarchy of control is a well-established and effective framework for managing health and safety risks in New Zealand workplaces. It helps businesses prioritise the most effective methods of hazard control - starting with elimination and ending with personal protective equipment.
By following this structure, organisations not only meet their obligations under the Health and Safety at Work Act 2015 (HSWA) but also foster a culture of prevention over reaction.
In this article, we answer the big questions:
What is the hierarchy of control?
How do you implement it effectively?
What are the common challenges and solutions?
Why does it matter for your team and your bottom line?
What Is the Hierarchy Of Control?
The hierarchy of control outlines five levels of control strategies ranked by effectiveness:
Elimination – Remove the hazard entirely
Substitution – Replace the hazard with something safer
Engineering Controls – Isolate people from the hazard
Administrative Controls – Change how people work
Personal Protective Equipment (PPE) – Use gear to protect people
Each level builds upon the last. The higher up the hierarchy, the more reliable the control.
The hierarchy of control ranks workplace safety strategies from most to least effective: elimination, substitution, engineering controls, administrative controls, and PPE.
Elimination: The Top Level of the Hierarchy Of Control
Elimination is the gold standard in the hierarchy of control. If you can completely remove a hazard, there is no longer any risk associated with it.
Examples of elimination in action:
Replacing manual processes with automation
Removing a hazardous substance from a production process
Eliminating the need for working at height by redesigning equipment
Though not always possible, this approach should be the first consideration during any risk assessment.
Substitution: Safer Alternatives That Reduce Risk
When elimination isn't viable, substitution offers a powerful alternative. This step involves swapping out the hazard for something less dangerous.
Real-world substitution examples include:
Using water-based paints instead of solvent-based ones
Switching manual lifting with a vacuum hoist or lift-assist tool
Replacing corrosive cleaning chemicals with eco-friendly alternatives
This level of control sits just beneath elimination and can significantly reduce the potential for harm.
Engineering Controls: Design That Defends
Engineering controls come third in the hierarchy of control. They don’t remove the hazard - but they do isolate workers from it.
Effective engineering controls include:
Installing fixed guardrails on elevated platforms
Enclosing noisy machinery to reduce exposure
Installing local exhaust ventilation to remove fumes and dust
Unlike PPE, these controls don’t rely on individual behaviour. They’re often considered more reliable for long-term risk reduction.
Administrative Controls in the Hierarchy Of Control
Administrative controls are about systems, processes, and behaviours. These strategies don’t eliminate hazards, but they reduce exposure by changing the way people work.
Common administrative controls:
Implementing safe work procedures
Running regular safety training sessions
Setting rosters to limit fatigue-related risk
Induction and supervision policies for new staff
They’re especially useful when engineering controls aren’t feasible—though they often need more oversight and reinforcement.
Personal Protective Equipment: The Final Line of Defence
At the base of the hierarchy of control is PPE. This includes helmets, gloves, goggles, respirators, and protective clothing.
While PPE plays a role, it has limitations:
It doesn’t eliminate the hazard
It requires correct fit and consistent use
It can fail due to damage, misuse, or neglect
Training, maintenance, and periodic audits are essential for PPE to remain effective.
How to Apply the Hierarchy Of Control in the Workplace
To make the hierarchy of control work in your organisation, follow these steps:
1. Conduct a Risk Assessment
Identify hazards, assess the level of risk, and decide on the appropriate control measures. Use tools like a Compliance Compass Assessment to guide the process.
2. Involve Your People
Frontline workers often have the best insight into day-to-day risks. Engaging them fosters buy-in and practical solutions.
3. Choose Controls Based on the Hierarchy
Start at the top (elimination) and work down the list. Always justify why a more effective control wasn't possible.
4. Monitor and Review
Are the controls working? What’s changing in your environment? Safety isn’t “set and forget.” Regular reviews are critical.
Want to discuss your safety goals?
Contact Advanced Safety for professional guidance and support.
Contact Us TodayThe Hierarchy Of Control and Legal Compliance
New Zealand's HSWA 2015 requires a proactive approach to risk management. Following the hierarchy of control supports your PCBU (Person Conducting a Business or Undertaking) duties under the Act, particularly:
Section 30: Managing risks
Section 36: Primary duty of care
Section 45: Worker responsibilities
Failing to consider higher-level controls before defaulting to PPE can lead to enforcement actions by WorkSafe NZ.
Challenges in Applying the Hierarchy Of Control
Even well-intentioned organisations encounter hurdles. Here are a few—and how to overcome them:
Challenge: Cost Constraints
Solution: Prioritise high-risk areas. Seek scalable solutions that offer value over time, such as automation that reduces both risk and labour costs.
Challenge: Change Resistance
Solution: Explain the “why.” Share real-world examples of incidents prevented through good controls. Safety culture starts with communication.
Challenge: Misuse of PPE
Solution: Train, supervise, and audit. Make sure PPE is comfortable, appropriate, and used as part of a broader safety system.
Benefits of Using the Hierarchy Of Control
Adopting the hierarchy of control leads to measurable improvements:
Fewer injuries and incidents
Lower insurance premiums and fewer legal liabilities
Greater staff engagement and trust
Enhanced compliance and audit readiness
Stronger health and safety culture
Businesses that invest in higher-order controls often see not just fewer injuries - but better productivity too.
Hierarchy Of Control in Construction and Manufacturing
In sectors like construction, engineering, and manufacturing, the hierarchy of control has immediate and visible impact.
Example 1: Construction Site Fall Hazards
Elimination: Redesign site layout to remove elevated tasks
Engineering: Install scaffolds with guardrails
Administrative: Daily briefings and supervision
PPE: Harnesses, helmets, steel-capped boots
Example 2: Manufacturing Chemical Exposure
Substitution: Replace solvent with a water-based option
Engineering: Fume extraction systems
Administrative: Rotating staff to limit exposure time
PPE: Gloves, aprons, respirators
These layered approaches demonstrate the practical application of each control level.
Want to Improve Your Workplace Safety?
Contact Advanced Safety for expert guidance and support.
Contact Us TodayFinal Thoughts on the Hierarchy Of Control
The hierarchy of control is more than just a legal requirement - it's a practical, evidence-based approach that empowers your business to manage risks before they turn into incidents. By embedding this framework into your workplace culture, you demonstrate not only compliance but leadership in protecting your people.
