12/02/2021

Machine Safety Training Course Module 1

Prevention of Machinery Hazards
TÜV Rheinland

Introduction of Risk Assessment in Machinery Safety

ISO 12100
Honda Prospect Motor Feb 2021
Trainer: Ivan Stevanus Chandra

Course Program
Machinery Safety Adopting ISO 12100

Morning Session 1
08.30-10.30
Module 1 Definition and Introduction of Machinery Hazards

Morning Session 2
10.45-12.00
Module 2 Method and Tools of Machinery Safety

After Noon Session 1

13.00-15.00
Module 3 Risk Estimation and Risk Reduction – Concept and Application

After Noon Session 2

15.00-17.00
15.00-15.45 Module 4 Study Cases
16.00-17.00 Module 5 Workshop and Presentation

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A few Words about me

Home town:
01. Education:
Jakarta
01 Bachelor in Occupational Safety and Health
Master in Risk Engineering and Risk Management

02. Working Experiences:

- 2 years in Manufacturing
02 - 6 Years Working Experience in
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EPC and Oil & Gas company
- 5 years in petrochemical
03. Hobbies and work life balance:
 Movies
 Sports: Jogging, Spinning, Hiking/Touring, Chess
 Badminton and Football
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 Travelling

Penyemangat Pagi

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Module 1: Definition and Introduction of Machinery Hazards

Welcome to TÜV Rheinland Training

Introduction to Machinery Safety
2021

The aim of this course

Is to understand and be able to:

Principles of Machinery hazards

Machinery Hazards Prevention

Principles of hazards controlling and

reducing

Introduction of safeguarding and

protective devices

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Module 1
1. Introduction

Accident Statistic compare with Fatality in Indonesia

Data of Accident and Incident work related from 2001-2020
Tahun Jumlah Kasus Kecelakaan Kerja Jumlah Kasus Meninggal

200,000 2001 104,714 1,768

2002 103,804 1,903
180,000
2003 105,846 1,748
160,000 2004 95,418 1,736
140,000
2005 99,023 2,045
2006 95,624 1,784
120,000 2007 83,714 1,883
100,000 2008 93,823 2,124
2009 96,134 2,114
80,000
2010 98,712 2,191
60,000 2011 94,491 2,144
2012 103,074 2,332
40,000
2013 103,235 2,438
20,000 2014 105,383 2,375
0
2015 110,285 2,308
2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

2016 101,367 2,382

2017 123,041 3,000
2018 173,415 Not available
2019 114,000 Not available
Accident Statistics still up trending in Indonesian soil 2020 177,000 3279
from the last 20 years.

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US Fatal Work Injuries in private manufacturing by major event, 2017

Fatalities in US work related by type of event

Fatal work injuries in private manufacturing by

major event, 2017 (U.S Bureau of Labor Statistic)
No Event No of
Fatality
1 Transportation incidents 79
2 Contact with objects and
79
equipment
3 Fall, slip, trip 50
4 Exposure to harmful substances
41
or environments
5 Violence and other injuries by
31
persons or animals
6 Fire or explosion 21
Total 301

Accident Involving Machine

National Safety Council Injury Facts – 2019 Edition - USA

No Nature of Injury Private Sector Manufacturing

1 Fractures 85,710 13,400  Top 3 Injury for
2 Sprains, strains or tears 295,180 32,470 Manufacturing:
3 Amputations 6,020 2,810 1. Sprains, strains or
Cuts, lacerations or punctures tears.
4 72,110 15,380
2. Soreness or pain
5 Bruises or contusions 80,640 9,050
3. Cuts, lacerations or
6 Chemical burns or corrosions 4,040 900 punctures
7 Heat (Thermal) burns 14,890 2,050
8 Multiple traumatic injuries 23,210 2,200
9 Soreness or pain 157,440 16,790
10 CTS 4,180 1,580
11 Tendonitis 1,420 380
12 All other 125,760 19,040
Total 870,600 116.050

Home - Injury Facts (nsc.org

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Evaluation and Short Estimation

General Assessment

• Accident and Incident in many industries become critical key

performance indicator (lagging).
• Road incident (external) and Machinery related incident (internal)
are most critical finding.
• Understanding the hazard in the workplace is the most important
things.
• Training (on job training) is a key element to learn working
properly and avoid any unwanted situation that leads to incident or
accident.
“People say that accidents are due to human error, which is like saying falls are due to gravity” –
Trevor Kleitz

Module 1
2. Definition and Introduction of Machinery Hazards

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Definition and Terminology

Hazard VS Risk

• Hazard Definition
 Potential source of harm, ISO 12100: 2010.
 Any source, situation or activity that potentially causing injury or disease, ISO 45001:2016.

 In general, hazards are classified into 5 types:
 Biological Hazard;
 Chemical Hazard;
 Physical/Mechanical Hazard;
 Psychosocial Hazard;
 Biomechanics/Ergonomical Hazard
 Hazards generated by the neglect of ergonomic
principles in the design of machinery
 In ISO 12100, hazards are to be taken into account:
 Mechanical hazards
 Electrical hazards
 Thermal hazards
 Hazards generated by noise
 Hazards generated by vibration
 Hazards generated by radiation
 Hazards generated by materials and substances
 Hazards generated by the neglect of ergonomic
principles in the design of machinery

Definition and Terminology

Hazard VS Risk

• Risk Definition
 Combination of the probability of occurrence of harm and the severity of that harm, ISO 12100:2010.
 Potential losses that can be caused if in contact with hazards or the failure of a function.
 Usually assessed based on Frequency Value (Probability) and Severity value.
 Risk = Probability x Severity  R = P x S

Element of risk, ISO 12100: 2010

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3. Machinery Hazards

Machinery Hazard - 1
Typical Hazard in Manufacturing – ISO 12100

• Mechanical Hazard
 Mechanical hazards cover all hazards caused by mechanical parts of the machine.
 From Sharp edges to rotating and moving parts.
 Cutting.
 Crushing.
 Shearing etc.

 Mechanical Hazard (Consequence)

 Injury such as hand, leg, head etc.
 Handicapped or fatality.

Pinch point of two gears

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Machinery Hazard - 2
Typical Hazard in Manufacturing – ISO 12100

• Electrical Hazard
 All hazards that involve electrical parts of the
Direct contact Indirect contact
machine.
 Direct contact and indirect contact with
electrical source.
 From Sharp edges to rotating and moving
parts.
 Electrocution
 Arcs
 thermal radiation etc.

Machinery Hazard - 2
Typical Hazard in Manufacturing – ISO 12100

• Electrical Hazard (Consequence)

Besar Arus Efek/konsekuensi
Tegangan
200 V 1 mA Ambang Perasaan Sensasi Kesemutan

500 V 5 mA Ambang Batas Bahaya yang masih mampu diterima oleh manusia

1000 V 10-20 mA Tubuh mulai kejang-kejang dan tidak dapat melepaskan diri

10.000 V 10-20 mA Semakin Fatal, namun pernafasan masih normal (jika berlanjut dapat
menyebabkan kematian
60.000 V 6A Sangat Fatal, kejang-kejang terjadi terus-menerus disertai gangguan
nafas dan menyebabkan luka bakar hingga kematian (hangus)

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Machinery Hazard - 3
Typical Hazard in Manufacturing – ISO 12100

• Thermal Hazard
 Hazards caused by very hot and very cold.
 Parts of high and low temperature and radiation form heat sources including:
 Explosion.
 flames.
 Open fire etc.

 Thermal Hazard (Consequence)

 Discomfort.
 Dehydration.
 Serious injury (Burn or frostbite)
 Radiation injury.

Machinery Hazard - 4
Typical Hazard in Manufacturing – ISO 12100

• Noise Hazard
 Any sound that the human ear finds unpleasing
and disruptive to concentration.
 Source can be continuous or intermittent:
 Pumps, rotor, motor, moving part of mechanical
part.
 Pneumatic whistling, etc.

 Noise Hazard (Consequence)

 Discomfort, unwanted feeling and disoriented while
working, stress
 Noise Induced Hearing Loss.
 Long term exposure : deaf

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Machinery Hazard - 5
Typical Hazard in Manufacturing – ISO 12100

• Vibration Hazard
 Beside noise, vibration is known as other
outcome of moving parts of machine.
 Origin i.e.:
 Cavitation phenomena, misalignment of moving
parts.
 Scraping surfaces; unbalance rotating parts, worn
parts etc.

 Vibration Hazard (Consequence)

 Discomfort, low-back morbidity
 Neuro/osteo disorder such as trauma of spine
 Vascular disorder etc.

Machinery Hazard - 6
Typical Hazard in Manufacturing – ISO 12100

• Radiation Hazard
 Ionizing radiation can affect the atoms of human
body  damage DNA.
 Sources radioactive radiation in form of X-rays,
alpha, beta and gamma rays.

 Radiation Hazard (Consequence)

 Atomic blast:
 high level – skin burns/acute radiation syndrome.
 Low level – long term health effect could be
cancer.

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Machinery Hazard - 7
Typical Hazard in Manufacturing – ISO 12100

• Material/Substance Hazard
 Term “material/substance” = liquids, gasses, solids,
fumes etc..
 This hazard can cause harm to human body when
exposed via skin contact, ingestion or inhalation.

• Material/Substance Hazard (Mitigation)

 Fire extinguisher method (Cooling, Starvation,,
smothering); technique (pull, aim, squeeze and
sweep)
 Extinguishing types:
 CO2, Foam, Spray, multi-purpose ABC (with
pressure gauge only) etc.

Machinery Hazard - 7
Typical Hazard in Manufacturing – ISO 12100

• Chemical/Substance Hazard (Consequence)

 Fire or explosion.
 Acute effects: sensitization, breathing difficulties,
suffocation, poisoning, infection,
 Long term effects: mutation, cancer, effects on
reproductive capability

Burn Impact on Human body:

- Third Class – Full thickness: destroy the epidermis and
dermis; damage underlying bones, muscles etc.
- Second Class – Partial thickness : Blisters, swollen and
painful.
- First Class – Superficial burns : red, dry, painful, no
blisters

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Machinery Hazard - 8
Typical Hazard in Manufacturing – ISO 12100

• Ergonomic Hazard
 Related with work tools, work environment, or work methods  designed
to be incompatible with the human body's physical and psychological
capabilities.
 Precaution:
 How to work, work position, and posture that are not appropriate when doing
work.
 Design of work tools and workplaces that are not in accordance with the
anthropometry of the workforce.
 Lifting loads that exceed work capacity.
 Ergonomic Hazard (Consequence)
 Sprain, Injury to muscles - MSD (Muscular Skeletal Disorder).
 Nerves, muscles, joints disorder – LBP (Low Back Pain) and CTD
(Cumulative trauma disorders).

Ergonomic Hazard

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Coffee break

4. Strategy for Risk Assessment and Risk Reduction

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Strategy for Risk Assessment and Risk Reduction

To implement RA and RR, designer shall take following actions

Order to Perform RA and RR, ISO 12100-2010:

a) Determine the limits of the machinery, which include the intended use and any reasonably foreseeable
misuse thereof;
b) Identify the hazards and associated hazardous situation;
c) Estimate the risk for each identified hazard and hazardous situation;
d) Evaluate the risk and take decisions about the need for risk reduction;
e) Eliminate the hazard or reduce the risk associated with the hazard by means of protective measures.
 Actions a) to d) are related to RA
 Actions e) related to RR.
Objective is the greatest practicable risk reduction with consideration of four factor below:
1. The safety of the machine during all the phases of its life cycle;
2. The ability of the machine to perform its function;
3. The usability of the machine;
4. The manufacturing, operational and dismantling costs of the machine.
Risk Assessment and Risk Reduction Process

Conceptual
Review

User Input
Review

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Risk Assessment

Risk Assessment and Risk Evaluation

How to perform Risk Assessment and Risk Evaluation

Start – Determination of limits of the

machinery:
a) Use limits (intended use and reasonably
foreseeable misuse);
b) Space limits (range of movement, space
requirements of HMI and Power supply);
c) Time limits (life limit of the machinery &
components; service intervals);
d) Other limits (Properties of material to be
processed, housekeeping and
environmental).

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Risk Assessment and Risk Evaluation

How to perform Hazard Identification

Hazard Identification – systematic

identification of reasonably foreseeable
hazards:
a) Human Interaction during the whole life cycle
of the machine (setting, testing, start-up,
mode of operation, trouble-shooting, PM/CM;
b) Possible states of the machine;
 Intended function – operates normally
 Not performed intendedly i.e., malfunction.
c) Unintended behavior of the operator or
reasonably foreseeable misuse of the
machine) i.e.:
 Loss of control by operator.
 behavior resulting from lack of
concentration or carelessness. Etc.

Risk Assessment and Risk Evaluation

How to perform Risk Estimation

Risk Estimation:
a) Element of risk;
b) Aspects to be considered during risk
estimation;
 Person exposed;
 Type, frequency and duration of exposure
 Relationship between exposure and
effects;
 Human factors;
 Suitable of protective measures;
 Possibility of defeating or circumventing
protective measures;
 Ability to maintain protective measures.

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Risk Assessment and Risk Evaluation

How to perform Risk Evaluation

After Risk Identification and Estimation

completed:
a) Shall be carried out if risk reduction is
required;
b) Outcome of RE  get overview of all risk
related activities;
 Risk mapping (Comparison of risks)
 Priority based on the result or Risk
Estimation – Adequate risk reduction.

 follow-up to 3 steps of risk reduction.

Risk Reduction
How to perform Risk Reduction

3 steps for performing RR:

Step 1: Inherently safe design measures
Eliminate hazards or reduce the associated risks:
1. Design features of the machine itself and/or
2. Interaction between the exposed persons and the machine.
Step 2: Safeguarding and/or complementary protective measures;
1. Consider Intended use and the reasonably foreseeable misuse.
2. Selected safeguarding and complementary protective measures (if not
practicable to eliminate or reduce the hazards)
Step 3: Information for use
1. Where risks remain, safeguarding
2. Adoption of complementary protective measures
 residual risks shall be identified in the information for use.

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Risk Reduction Principles

3-Step method – ISO 12100, 2010

Hierarchy of Control/Risk Reduction Measures

Hazard Hierarchy Control System:
Inherently safe design (Elimination or
Substitution)

Safeguarding and complementary

protective measures (Engineering
Control)

Information for Use (Human Factor

Improvement)

Organizational Control (Administrative

Control)

Personal Protective Equipment

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Step 1 – Inherently Safe Design (ISD) Measures

Highest Rank for RR Measurement

Step 1: Inherently Safe Design Measures

Eliminate hazards or reduce the associated risks:
1. Design features of the machine itself and/or
2. Interaction between the exposed persons and the machine.

Step 1 – Inherently Safe Design (ISD) Measures

Eliminate hazards or reduce

1. Consideration of geometrical factors and physical aspects.

2. General technical knowledge of machine design.
3. Choice of appropriate technology.
4. Applying principle of positive mechanical action.
5. Provisions for stability, Maintainability and observing ergonomic.
6. Review on Electrical, Pneumatic and Hydraulic hazards
7. ISD to control system
8. Minimizing probability of failure of safety functions (PFD) – redundancy.
9. Limiting exposure to hazards through reliability of equipment, mechatronics
of loading/unloading operation, location of setting and maintenance points
outside danger zones.

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Step 2 – Safeguarding and Complementary Protective Measures

Complementary Protective Measures
1. Protective Measures against Moving Parts
2. Access to the hazard zone during normal operation, machine
setting, process change over, fault-finding, cleaning or MTC
3. Selection and implementation of sensitive protective equipment
4. Protective measures for stability and others “PD’s”.

Step 3 – Information for Use

Risk Reduction by using Human Machine Interface (HMI)

Information for use = an integral part of design of a machine

At the machine:
- Warning signs, signals
- Warning devices
In the Instruction handbook.

 A guideline for operator to use the machine:

- Intended use
- Manual controls
- Setting, adjustment, modes and means for stopping
- Fault identification, location, repairing
- Possible PPE used if any

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3 Steps for doing Risk Reduction in ISO 12100, 2010

Inherently safe Safeguarding Information for

design measures sand use
complementary
protective
measures

Documentation of Risk Assessment and Risk Reduction

Comprehensive Risk Management

Contribution of Risk Assessment to the Risk management Process

including:
- Hazard Identification,
- Risk Analysis,
- Risk Evaluation
- Risk Treatment (Risk Reduction)
- Communication, Consultation, Monitoring and Review
Follow ISO 31010

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Thank You for Your Attention

Introduction of Risk Assessment in Safety of Machinery

Compliance with ISO 12100, 2010

Ivan Stevanus Chandra

Jakarta, 17-18 February 2021

www.tuv.com

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document nor any information or data contained therein may be used for any other purposes, or duplicated or disclosed in whole or in part, to any
third party, without the prior written authorization by TÜV Rheinland. This document is not complete without a verbal explanation (presentation)
of the content.
TÜV Rheinland AG

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