Procter Risk Assessment Calculator v7 1

www.machinesafety.co.uk info@machinesafety.co.
uk
How to use the Procter Risk Assessment Calculator
1 This Risk Assessment Calculator is designed to assist with carrying out risk assessments. However, it is the user's responsibility
to ensure that risk assessments are carried out in accordance with BS EN ISO 12100:2010 (Safety of machinery. General
principles for design. Risk assessment and risk reduction). If required, contact Procter Machine Safety for advice on specialists
who can assist with complex risk assessments. The Risk Assessment Calculator is based on Annex B of BS EN ISO 12100,
copies of which can be purchased from BSI.
It should be noted that the Machinery Directive 2006/42/EC and the corresponding Supply of Machinery (Safety) Regulations
1992 stipulate that the machine manufacturer or his representative must ensure that a risk assessment is carried out. In
addition, the Technical File must contain a copy of the risk assessment. It is therefore essential that the risk assessment
process is both carried out and documented adequately. The risk assessment can also assist in preparing the instructions for
the machine, as the Machinery Directive requires that information about the residual risks must be included in the instructions.
2 Seven worksheets are provided in this Risk Assessment Calculator: the Welcome page, Instructions (this page), a Look-Up
Table, a Summary page, two Machine pages and an Example Machine page. If more than two machines are being assessed,
copy one of the existing Machine worksheets and rename it as appropriate.
3 To use this Calculator, start by entering the company information on the Summary page. Then decide how many machines are
to be assessed and ensure that there are sufficient worksheets (one per machine). For each machine, enter the machine details
and other data in the table at the top of the worksheet. Then work down the list of hazards and decide which are applicable to
the machine in question. If a hazard is not applicable, mark N/A in the Comments column; the Risk Level column will
automatically show 'negligible' for these risks. For each applicable hazard, use the Look-Up Table to choose appropriate values
for the Likelihood of Occurrence (LO), Frequency of Exposure (FE), Degree of Possible Harm (DPH) and Number of Persons at
risk (NP). In addition to the list of hazards, there is also a list of hazardous situations (tasks) and a list of hazardous events. See
BS EN ISO 12100 for more information about these.
4 The Hazard Rating Number (HRN) is calculated automatically (LO x FE x DPH x NP) and colour-coded (see Look-Up Table). In
addition, the Calculator shows the corresponding Risk Level so that the user can decide if action is required. A risk is 'Negligible'
if there is very little risk to health and safety; a risk is 'Low, significant' if hazards exist that require control measures; a risk is
'High' if there are potentially dangerous hazards that require control measures to be implemented urgently; and a risk is
'Unacceptable' if continued operation in this state is unacceptable.
5 If action is required, it should be outlined in the first Action column. A further assessment must then be carried out to see the
effect on the HRN and Risk Level of taking the action. If the Risk Level is still too high, additional action can be specified in the
second Action column on the far right-hand side, after which a confirmatory assessment should be carried out.
6 Once the above procedure has been completed for each machine, the user can return to the Summary page and list the actions
required.
Procter Machine Safety - the UK's leading supplier of bespoke and modular machine guarding
Procter Machine Safety 11 Pantglas Industrial Estate, Bedwas, Caerphilly, CF83 8XD, UK
Tel: +44 (0)29 2085 5758
www.machinesafety.co.uk
info@machinesafety.co.uk
LO (Likelihood of Occurrence) FE (Frequency of Exposure) HRN Risk
0.033 Almost impossible Only in extreme circumstances 0.5 Annually 0-5 Negligible
1 Highly unlikely Though conceivable 1 Monthly 5-50 Low, significant
1.5 Unlikely But could occur 1.5 Weekly 50-500 High
2 Possible But unusual 2.5 Daily Over 500 Unacceptable
5 Even chance Could happen 4 Hourly HRN = LO x FE x DPH x NP
8 Probable Not surprising 5 Constantly
10 Likely To be expected
15 Certain No doubt
DPH (Degree of Possible Harm) NP (Number of Persons at risk)

0.1 Scratch or bruise 1 1-2 persons
0.5 Laceration or mild ill-effect 2 3-7 persons
2 Break of minor bone or minor illness (temporary) 4 8-15 persons
4 Break of major bone or major illness (temporary) 8 16-50 persons
6 Loss of one limb, eye, hearing (permanent) 12 50+ persons
10 Loss of two limbs or eyes (permanent)
15 Fatality
Source: Pilz Guide to Machinery Safety, 6th Edition

Company name:
Company address:
Assessment reference:
Assessment carried out by:
Assessment date:
Assessment checked by:
Assessment approved by:
Machines requiring action

Worksheet reference: Machine reference: Action required:
Assessment reference: Number of operatives:
Type of machine: Number of shifts per week:
Machine location: Usage (hours per month):
Machine description: Operating manuals:
Machine manufacturer: Standard operating procedures:
Machine model: Operatives' training record:
Machine serial number: Warning signs:
Modifications from 'as-supplied': Raw materials:
Energy sources: Maintenance manual:
Energy source ratings: Maintenance training record:
Safety measures: Access by untrained visitors:
Assessment date:
Type or group of Potential

Origin Comments
hazard consequences
Mechanical hazards Acceleration/deceleration Being run over
Being thrown
Crushing
Cutting or severing
Drawing-in or trapping
Entanglement
Friction or abrasion
Impact
Injection
Shearing
Slipping, tripping or falling
Stabbing or puncturing
Suffocation
Kinetic energy Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Angular parts Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Approach of a moving element to a Being run over
fixed part Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Cutting parts Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Elastic elements Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Falling objects Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Gravity Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Stored energy Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Height from the ground Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
High pressure Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Machinery mobility Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Moving elements Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Rotating elements Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Surface finish (rough or slippery) Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Sharp edges Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Instability Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Vacuum Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Other Other
Electrical hazards Arc Burn
Chemical effects
Effects on medical implants
Electrocution
Falling or being thrown
Fire
Projection of molten particles
Shock
Electromagnetic phenomena Burn
Chemical effects
Electrocution
Fire
Shock
Electrostatic phenomena Burn
Chemical effects
Electrocution
Fire
Shock
Live parts Burn
Chemical effects
Electrocution
Fire
Shock
Insufficient distance from live parts Burn
under high voltage Chemical effects
Electrocution
Fire
Shock
Overload Burn
Chemical effects
Electrocution
Fire
Shock
Parts becoming live under fault Burn
conditions Chemical effects
Electrocution
Fire
Shock
Short-circuit Burn
Chemical effects
Electrocution
Fire
Shock
Thermal radiation Burn
Chemical effects
Electrocution
Fire
Shock
Other Other
Thermal hazards Explosion Burn
Dehydration
Discomfort
Frostbite
Injuries from radiated heat
Scald
Flame Burn
Dehydration
Discomfort
Frostbite
Scald
Objects or materials with a high or Burn
low temperature Dehydration
Discomfort
Frostbite
Scald
Radiation from heat sources Burn
Dehydration
Discomfort
Frostbite
Scald
Other Other
Noise hazards Cavitation phenomena Discomfort
Loss of awareness
Loss of balance
Permanent hearing loss
Stress
Tinnitus
Tiredness
Other (eg mechanical or electrical)
as a consequence of an interference
with speech communication or with
acoustic signals.
Exhaust system Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
High-speed gas leak Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Manufacturing process (eg stamping, Discomfort

pressing, grinding) Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Moving parts Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Scraping surfaces Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Unbalanced rotating parts Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Whistling pneumatics Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Worn parts Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Other Other
Vibration hazards Cavitation phenomena Discomfort
Low-back disease
Neurological disorder
Osteo-articular disorder
Trauma of the spine
Vascular disorder
Misalignment of moving parts Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Mobile equipment Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Low-back disease
Trauma of the spine
Vascular disorder
Low-back disease
Trauma of the spine
Vascular disorder
Vibrating equipment Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Low-back disease
Trauma of the spine
Vascular disorder
Other Other
Radiation hazards Ionising radiation source Burn
Damage to eyes and skin
Effects on reproductive capability
Genetic mutation
Headache, insomnia, etc
Low-frequency electromagnetic Burn
radiation Damage to eyes and skin
Genetic mutation
Optical radiation (infrared, visible and Burn
ultraviolet), including laser Damage to eyes and skin
Genetic mutation
Radio frequency electromagnetic Burn
Genetic mutation
Other Other
Material/substance hazards Aerosol Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Biological and microbiological (viral Breathing difficulties, suffocation
or bacterial) agent Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Combustible Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Dust Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Explosive Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Fibre Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Flammable Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Fluid Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Fume Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Gas Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Mist Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Oxidiser Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Other Other
Ergonomic hazards Access Discomfort
Fatigue
Musculoskeletal disorder
Stress
Other (eg mechanical, electrical) as a
consequence of human error
Design or location of indicators and Discomfort
visual display units Fatigue
Stress
Design, location or identification of Discomfort
control devices Fatigue
Stress
Effort Discomfort
Fatigue
Stress
Flicker, dazzling, shadow, Discomfort
stroboscopic effect Fatigue
Stress
Local lighting Discomfort
Fatigue
Stress
Mental overload or underload Discomfort
Fatigue
Stress
Posture Discomfort
Fatigue
Stress
Repetitive activity Discomfort
Fatigue
Stress
Visibility Discomfort
Fatigue
Stress
Other Other
Hazards associated with the Dust and fog Burn
environment in which the machine Slight disease
is used Slipping or falling
Suffocation
Any other as a consequence of the
effect caused by the sources of the
hazards on the machine or parts of
the machine
Electromagnetic disturbance Burn
Slight disease
Slipping or falling
Suffocation
the machine
Lighting Burn
Slight disease
Slipping or falling
Suffocation
the machine
Moisture Burn
Slight disease
Slipping or falling
Suffocation
the machine
Pollution Burn
Slight disease
Slipping or falling
Suffocation
the machine
Snow Burn
Slight disease
Slipping or falling
Suffocation
the machine
Temperature Burn
Slight disease
Slipping or falling
Suffocation
the machine
Water Burn
Slight disease
Slipping or falling
Suffocation
the machine
Wind Burn
Slight disease
Slipping or falling
Suffocation
the machine
Lack of oxygen Burn
Slight disease
Slipping or falling
Suffocation
the machine
Other Other
Combined hazards eg repetitive activity + effort + high eg dehydration, loss of awareness,
environmental temperature heat stroke
Hazardous situations (tasks)
Phase of machine
Tasks Consequences Comments
lifecycle
Transport Lifting
Loading
Packing
Transportation
Unloading
Unpacking
Other tasks
Assembly, installation and Preparations for installation (eg
commissioning foundations, vibration isolators)
Assembly of the machine
Fixing, anchoring
Connection to energy supplies (eg
electricity, compressed air)
Connecting to disposal system (eg
for exhaust gases, waste water)
Adjustment of the machine and its
components
Fencing
Feeding, filling, loading of ancillary
fluids (eg lubricants, adhesives)
Testing
Running the machine without load
Trials with load or maximum load
Demonstration
Other tasks
Setting, teaching, programming Mounting or changing tools, tool-
and/or process changeover setting
Adjustment and setting of protective
devices and other components
Adjustment and setting or verification
of functional parameters of the
machine (eg speed, pressure, force,
travel limits)
Clamping/fastening the workpiece
Feeding, filling, loading of raw
material
Program verification
Functional test, trials
Verification of the final product
Other tasks
Operation Clamping/fastening the workpiece
material
Manual loading/unloading
Operating manual controls
Driving the machine
Minor adjustments and setting of
functional parameters of the machine
(eg speed, pressure, force, travel
limits)
Minor interventions during operation
(eg removing waste material,
eliminating jams, local cleaning)
Restarting the machine after
stopping/interruption
Unclamping/unfastening the
workpiece
Control/inspection
Supervision
Other tasks
Cleaning and maintenance Adjustments
Cleaning, disinfection
Dismantling/removal of parts,
components, devices of the machine
Housekeeping
Isolation and energy dissipation
Lubrication
Replacement of tools
Replacement of worn or damaged
parts
Resetting
Removal and disposal of spent fluids
Restoring fluid levels

Verification of parts, components,
devices of the machine
Other tasks
Fault-finding/trouble-shooting Adjustments
Fault-finding
Recovering from control and
protective devices failure
Recovering from jam
Repairing
Replacement of parts, components,
Rescue of trapped persons
Resetting
Other tasks
Dismantling and disabling Disconnection and energy dissipation
Dismantling
Lifting
Loading
Packing
Transportation
Unloading
Other tasks
Hazardous events
Origin related to Hazardous event Consequences Comments
Shape and/or superficial finishing Contact with rough surfaces

of accessible parts of the machine
Shape and/or superficial finishing
of accessible parts of the machine Contact with sharp edges and
corners, protruding parts
Moving parts of the machine Contact with moving parts
Contact with rotating open ends
Kinetic energy and/or potential Falling or ejection of objects
energy (gravity) of the machine,
parts of the machine, tools and
materials used, processed or
handled
Stability of the machine and/or Loss of stability
parts of the machine
Mechanical stiffness/strength of Deflection or break-up during
parts of the machine, tools, etc operation
Pneumatic and hydraulic Displacement of moving elements
equipment Projection of high-pressure fluids
Uncontrolled movements
Electrical equipment Direct contact
Disruptive discharge
Electric arc
Fire
Indirect contact
Short-circuit
Control system Dropping or ejection of a moving
parts of the machine or of a
workpiece clamped by the machine
Failure to stop moving parts
Machine action resulting from
inhibition (defeating or failure) of
protective devices
Uncontrolled movements (including
speed changes)
Unintended/unexpected start-up
Other hazardous events due to
failure(s) or poor design of the
control system
Materials and substances or Contact with objects with high or low
physical factors (temperature, temperature
noise, vibration, radiation and Emission of a substance that can be
environment) hazardous
Emission of a level of noise that can
be hazardous
interfere with a speech
communication or with acoustic
signals
Emission of a level of vibration that
can be hazardous
Emission of radiation fields that can
be hazardous
Harsh environmental conditions
Workstation and/or work process Excessive effort
design Human errors/misbehaviour
(unintentional and/or deliberately
induced by the design)
Loss of direct visibility of the working
area
Painful and/or tiring postures
Repetitive handling at high frequency
Other Other events

Initial assessment Re-assessment after taking action
Action required
LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

0 Negligible 0 Negligible

Action required


Action required

Action required
Action required
Action required
Assessment reference: Number of operatives:
Type of machine: Number of shifts per week:
Machine location: Usage (hours per month):
Machine description: Operating manuals:
Machine manufacturer: Standard operating procedures:
Machine model: Operatives' training record:
Machine serial number: Warning signs:
Modifications from 'as-supplied': Raw materials:
Energy sources: Maintenance manual:
Energy source ratings: Maintenance training record:
Safety measures: Access by untrained visitors:
Assessment date:

Origin Comments
hazard consequences
Mechanical hazards Acceleration/deceleration Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Angular parts Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Approach of a moving element to a Being run over
fixed part Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Cutting parts Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Elastic elements Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Falling objects Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Gravity Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Stored energy Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Height from the ground Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
High pressure Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Machinery mobility Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Moving elements Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Rotating elements Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Surface finish (rough or slippery) Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Sharp edges Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Instability Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Vacuum Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Other Other
Electrical hazards Arc Burn
Chemical effects
Electrocution
Fire
Shock
Electromagnetic phenomena Burn
Chemical effects
Electrocution
Fire
Shock
Electrostatic phenomena Burn
Chemical effects
Electrocution
Fire
Shock
Live parts Burn
Chemical effects
Electrocution
Fire
Shock
Insufficient distance from live parts Burn
under high voltage Chemical effects
Electrocution
Fire
Shock
Overload Burn
Chemical effects
Electrocution
Fire
Shock
conditions Chemical effects
Electrocution
Fire
Shock
Short-circuit Burn
Chemical effects
Electrocution
Fire
Shock
Thermal radiation Burn
Chemical effects
Electrocution
Fire
Shock
Other Other
Thermal hazards Explosion Burn
Dehydration
Discomfort
Frostbite
Scald
Flame Burn
Dehydration
Discomfort
Frostbite
Scald
Objects or materials with a high or Burn
low temperature Dehydration
Discomfort
Frostbite
Scald
Radiation from heat sources Burn
Dehydration
Discomfort
Frostbite
Scald
Other Other
Noise hazards Cavitation phenomena Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Exhaust system Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
High-speed gas leak Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Manufacturing process (eg stamping, Discomfort

pressing, grinding) Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Whistling pneumatics Discomfort

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.

Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Other Other
Vibration hazards Cavitation phenomena Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Misalignment of moving parts Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Mobile equipment Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Low-back disease
Trauma of the spine
Vascular disorder
Low-back disease
Trauma of the spine
Vascular disorder
Vibrating equipment Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Low-back disease
Trauma of the spine
Vascular disorder
Other Other
Radiation hazards Ionising radiation source Burn
Damage to eyes and skin
Genetic mutation
Low-frequency electromagnetic Burn
Genetic mutation
Optical radiation (infrared, visible and Burn
ultraviolet), including laser Damage to eyes and skin
Genetic mutation
Radio frequency electromagnetic Burn
Genetic mutation
Other Other
Material/substance hazards Aerosol Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Biological and microbiological (viral Breathing difficulties, suffocation
or bacterial) agent Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Combustible Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Dust Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Explosive Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Fibre Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Flammable Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Fluid Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Fume Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Gas Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Mist Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Oxidiser Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Other Other
Ergonomic hazards Access Discomfort
Fatigue
Stress
Design or location of indicators and Discomfort
visual display units Fatigue
Stress
Design, location or identification of Discomfort
control devices Fatigue
Stress
Effort Discomfort
Fatigue
Stress
Flicker, dazzling, shadow, Discomfort
stroboscopic effect Fatigue
Stress
Local lighting Discomfort
Fatigue
Stress
Mental overload or underload Discomfort
Fatigue
Stress
Posture Discomfort
Fatigue
Stress
Repetitive activity Discomfort
Fatigue
Stress
Visibility Discomfort
Fatigue
Stress
Other Other
Hazards associated with the Dust and fog Burn
environment in which the machine Slight disease
is used Slipping or falling
Suffocation
the machine
Electromagnetic disturbance Burn
Slight disease
Slipping or falling
Suffocation
the machine
Lighting Burn
Slight disease
Slipping or falling
Suffocation
the machine
Moisture Burn
Slight disease
Slipping or falling
Suffocation
the machine
Pollution Burn
Slight disease
Slipping or falling
Suffocation
the machine
Snow Burn
Slight disease
Slipping or falling
Suffocation
the machine
Temperature Burn
Slight disease
Slipping or falling
Suffocation
the machine
Water Burn
Slight disease
Slipping or falling
Suffocation
the machine
Wind Burn
Slight disease
Slipping or falling
Suffocation
the machine
Lack of oxygen Burn
Slight disease
Slipping or falling
Suffocation
the machine
Other Other
environmental temperature heat stroke
Phase of machine
lifecycle
Transport Lifting
Loading
Packing
Transportation
Unloading
Unpacking
Other tasks
commissioning foundations, vibration isolators)
Assembly of the machine
Fixing, anchoring
Connection to energy supplies (eg
electricity, compressed air)
Connecting to disposal system (eg
Adjustment of the machine and its
components
Fencing
fluids (eg lubricants, adhesives)
Testing
Running the machine without load
Trials with load or maximum load
Demonstration
Other tasks
and/or process changeover setting
devices and other components
travel limits)
Clamping/fastening the workpiece
material
Program verification
Functional test, trials
Other tasks
Operation Clamping/fastening the workpiece
material
Manual loading/unloading
Operating manual controls
Driving the machine
limits)
eliminating jams, local cleaning)
stopping/interruption
Unclamping/unfastening the
workpiece
Control/inspection
Supervision
Other tasks
Cleaning and maintenance Adjustments
Cleaning, disinfection
Housekeeping
Lubrication
Replacement of tools
Replacement of worn or damaged
parts
Resetting
Restoring fluid levels

Other tasks
Fault-finding/trouble-shooting Adjustments
Fault-finding
protective devices failure
Recovering from jam
Repairing
Replacement of parts, components,
Rescue of trapped persons
Resetting
Other tasks
Dismantling and disabling Disconnection and energy dissipation
Dismantling
Lifting
Loading
Packing
Transportation
Unloading
Other tasks
Hazardous events
Shape and/or superficial finishing Contact with rough surfaces

corners, protruding parts
Moving parts of the machine Contact with moving parts
Contact with rotating open ends
handled
parts of the machine
parts of the machine, tools, etc operation
Pneumatic and hydraulic Displacement of moving elements
equipment Projection of high-pressure fluids
Uncontrolled movements
Electrical equipment Direct contact
Disruptive discharge
Electric arc
Fire
Indirect contact
Short-circuit
parts of the machine or of a
workpiece clamped by the machine
Failure to stop moving parts
protective devices
speed changes)
Unintended/unexpected start-up
control system
physical factors (temperature, temperature
environment) hazardous
be hazardous
signals
can be hazardous
be hazardous
Harsh environmental conditions
Workstation and/or work process Excessive effort
induced by the design)
area
Painful and/or tiring postures
Other Other events

Action required


Action required


Action required

Action required
Action required
Action required
Assessment reference: 0101 Number of operatives: 1
Type of machine: Cable re-reeler Number of shifts per week: 5
Machine location: Building 01, cable section Usage (hours per month): 35
Machine description: Machine re-reels cable following Operating manuals: Yes, as supplied
marking or measuring operations on
other machines.
Machine manufacturer: CableMagic Standard operating procedures: Yes, adjacent to machine.
Machine model: CM01 Operatives' training record: Yes, held in HR file.
Machine serial number: 0000123 Warning signs: One, relating to pinch hazard.
Modifications from 'as-supplied': None Raw materials: Electrical cable up to 3mm diameter.
Energy sources: Electricity, compressed air Maintenance manual: Yes, held in maintenance dept (last
serviced 3 months ago).
Energy source ratings: 240V AC; 6bar pressure Maintenance training record: Maintenance manager trained during
installation of machine.
Safety measures: Emergency stop button connected to Access by untrained visitors: None
safety relay - isolates power and
operates dump valve.
Assessment carried out by: A. Person
Assessment date: 16 September 2020
Assessment checked by: A. N. Other Person
Assessment approved by: A. Third Person

Origin Comments
hazard consequences
Mechanical hazards Acceleration/deceleration Being run over N/A
Being thrown N/A
Crushing N/A
Cutting or severing N/A
Drawing-in or trapping N/A
Entanglement N/A
Friction or abrasion N/A
Impact N/A
Injection N/A
Shearing N/A
Slipping, tripping or falling N/A
Stabbing or puncturing N/A
Suffocation N/A
Being thrown
Crushing Rotating cable reel (approx 5kg, card
or plastic flanges, no sharp edges)
could become detached.
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Angular parts Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Approach of a moving element to a Being run over N/A
fixed part Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Cutting parts Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Elastic elements Being run over N/A
Being thrown N/A
Crushing N/A
Drawing-in or trapping Pneumatic-actuated (10mm cylinder)
'dancing arm' could trap hand or
finger
Entanglement N/A
Impact Pneumatic-actuated (10mm cylinder)
'dancing arm' could strike hand or
finger
Injection N/A
Shearing N/A
Suffocation N/A
Falling objects Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Gravity Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Stored energy Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Height from the ground Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
High pressure Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Stabbing or puncturing Escaping compressed air could enter
the blood stream
Suffocation N/A
Machinery mobility Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Moving elements Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Rotating elements Being run over N/A
Being thrown N/A
Crushing Rotating cable reel (approx 5kg, card
or plastic flanges, no sharp edges)
could become detached.
Cutting or severing Rotating cable reel (card or plastic
flanges, no sharp edges, up to 100
rpm, max 250mm dia).
Drawing-in or trapping Nip point where cable is wound onto
reel
Entanglement Exposed end of shaft on which cable
reel is mounted
Friction or abrasion Rotating cable reel (card or plastic
flanges, no sharp edges, up to 100
rpm, max 250mm dia).
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Surface finish (rough or slippery) Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Friction or abrasion Potential for inadequately finished
cast, machined and other surfaces
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Sharp edges Being run over N/A
Being thrown N/A
Crushing N/A
Cutting or severing Potential for inadequately finished
cast, machined and other edges
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Instability Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact Snagged cable could cause re-reeler
to tip over
Injection N/A
Shearing N/A
Suffocation N/A
Vacuum Being run over N/A
Being thrown N/A
Crushing N/A
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Other Other N/A
Electrical hazards Arc Burn N/A
Chemical effects N/A
Effects on medical implants N/A
Electrocution N/A
Falling or being thrown N/A
Fire N/A
Projection of molten particles N/A
Shock N/A
Electromagnetic phenomena Burn N/A
Effects on medical implants Potential for stray EMI
Electrocution N/A
Fire N/A
Shock N/A
Electrostatic phenomena Burn N/A
Electrocution N/A
Fire N/A
Shock
Static charge could build up where

cable passes over pulleys
Live parts Burn
All electrical components contained
within earthed metal machine casing
Electrocution
Fire N/A
Shock
Insufficient distance from live parts Burn N/A
under high voltage Chemical effects N/A
Electrocution N/A
Fire N/A
Shock N/A
Overload Burn Motor control incorporates overload
protection
Electrocution N/A
Fire N/A
Shock N/A
conditions All electrical components contained
Electrocution
Fire N/A
Shock
Short-circuit Burn
Electrocution
Fire N/A
Shock
Thermal radiation Burn N/A
Electrocution N/A
Fire N/A
Shock N/A
Other Other N/A
Thermal hazards Explosion Burn N/A
Dehydration N/A
Discomfort N/A
Frostbite N/A
Injuries from radiated heat N/A
Scald N/A
Flame Burn N/A
Dehydration N/A
Discomfort N/A
Frostbite N/A
Scald N/A
Objects or materials with a high or Burn N/A
low temperature Dehydration N/A
Discomfort N/A
Frostbite N/A
Scald N/A
Radiation from heat sources Burn N/A
Dehydration N/A
Discomfort N/A
Frostbite N/A
Scald N/A
Other Other N/A
Noise hazards Cavitation phenomena Discomfort N/A
Loss of awareness N/A
Loss of balance N/A
Permanent hearing loss N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
Other (eg mechanical or electrical) N/A
acoustic signals.
Exhaust system Discomfort N/A

Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
High-speed gas leak Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
Manufacturing process (eg stamping, Discomfort N/A

pressing, grinding) Loss of awareness N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
Only source of significant noise is

gearmotor
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Scraping surfaces Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Unbalanced rotating parts Discomfort Only low noise from out-of-balance
cable drum
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Whistling pneumatics Discomfort Potential for leaks from pneumatic
components
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Worn parts Discomfort Gearmotor and bearings are lightly
stressed, so unlikely to wear
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Other Other N/A
Vibration hazards Cavitation phenomena Discomfort N/A
Low-back disease N/A
Neurological disorder N/A
Osteo-articular disorder N/A
Trauma of the spine N/A
Vascular disorder N/A
Misalignment of moving parts Discomfort N/A
Mobile equipment Discomfort N/A
Scraping surfaces Discomfort N/A
Unbalanced rotating parts Discomfort No human contact with machine
while it is running
Vibrating equipment Discomfort No human contact with machine
while it is running
Worn parts Discomfort Gearmotor and bearings are lightly
stressed, so unlikely to wear
Other Other N/A
Radiation hazards Ionising radiation source Burn N/A
Damage to eyes and skin N/A
Effects on reproductive capability N/A
Genetic mutation N/A
Headache, insomnia, etc N/A
Low-frequency electromagnetic Burn N/A
radiation Damage to eyes and skin N/A
Optical radiation (infrared, visible and Burn N/A
ultraviolet), including laser Damage to eyes and skin N/A
Radio frequency electromagnetic Burn N/A
radiation Damage to eyes and skin N/A
Other Other N/A
Material/substance hazards Aerosol Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Biological and microbiological (viral Breathing difficulties, suffocation N/A
or bacterial) agent Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Combustible Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Dust Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Explosive Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Fibre Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Flammable Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Fluid Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Fume Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Gas Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Mist Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Oxidiser Breathing difficulties, suffocation N/A
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation N/A
Other Other N/A
Ergonomic hazards Access Discomfort N/A
Fatigue N/A
Musculoskeletal disorder N/A
Stress N/A
consequence of human error N/A
Design or location of indicators and Discomfort Illuminated on/off switch and
visual display units pneumatic pressure gauge well
placed for easy visibility
Fatigue N/A
Stress N/A
Design, location or identification of Discomfort Illuminated on/off switch and
control devices pneumatic regulator well placed for
easy accessibility
Fatigue N/A
Stress N/A
Effort Discomfort Full cable reel max 5kg so minimal
effort required
Fatigue Full cable reel max 5kg so minimal
effort required
Stress N/A
Flicker, dazzling, shadow, Discomfort N/A
stroboscopic effect
Flicker, dazzling, shadow,
stroboscopic effect Fatigue N/A
Stress N/A
Local lighting Discomfort N/A
Fatigue N/A
Stress N/A
Mental overload or underload Discomfort N/A
Fatigue N/A
Stress N/A
Posture Discomfort N/A
Fatigue N/A
Stress N/A
Repetitive activity Discomfort N/A
Fatigue N/A
Stress N/A
Visibility Discomfort N/A
Fatigue N/A
Stress N/A
Other Other N/A
Hazards associated with the Dust and fog Burn N/A
environment in which the machine Slight disease N/A
is used Slipping or falling N/A
Suffocation N/A
the machine N/A
Electromagnetic disturbance Burn N/A
Slight disease N/A
Slipping or falling N/A
Suffocation N/A
the machine N/A
Lighting Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Moisture Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Pollution Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Snow Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Temperature Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Water Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Wind Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Lack of oxygen Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Other Other N/A
environmental temperature heat stroke N/A
N/A
N/A
N/A
N/A
N/A
N/A
Phase of machine
lifecycle
Transport Lifting Check if safe for one person to lift
Discomfort, musculoskeletal disorder machine unassisted
Loading N/A
Packing N/A
Transportation N/A
Unloading N/A
Unpacking N/A
Other tasks N/A
commissioning foundations, vibration isolators) N/A
Assembly of the machine N/A Supplied fully assembled
Fixing, anchoring Potential injury during drilling of holes Use good working practices
Connection to energy supplies (eg Potential for electric shock and injury
electricity, compressed air) from compressed air Standard mains lead supplied with
machine; use good working practices
when connecting to air supply
Connecting to disposal system (eg N/A
Adjustment of the machine and its Impact from dancing arm Supply machine with regulator turned
components down to minimum; include warning in
instructions
Fencing N/A
fluids (eg lubricants, adhesives) N/A
Testing N/A
Running the machine without load N/A
Trials with load or maximum load N/A
Demonstration N/A
Other tasks N/A
and/or process changeover setting N/A
devices and other components N/A
travel limits) N/A
Clamping/fastening the workpiece N/A
material N/A
Program verification N/A
Functional test, trials N/A
Verification of the final product N/A
Other tasks N/A
Operation Clamping/fastening the workpiece Cable reel could work loose Ensure clamp nut is tight
material N/A
Manual loading/unloading N/A Max cable drum weight is 5kg
Operating manual controls N/A
Driving the machine N/A
limits) N/A
eliminating jams, local cleaning) N/A
stopping/interruption N/A
Machine could restart unexpectedly if Ensure machine is switched off
Unclamping/unfastening the dancing arm moved from bottom before removing cable drum
workpiece position
Control/inspection N/A
Supervision N/A
Verification of the final product N/A
Other tasks N/A
Cleaning and maintenance Adjustments N/A
Cleaning, disinfection N/A
components, devices of the machine N/A
Housekeeping N/A
Isolation and energy dissipation N/A
Lubrication N/A
Replacement of tools N/A
Replacement of worn or damaged All components specified to last the
parts N/A lifetime of the machine
Resetting N/A
Removal and disposal of spent fluids N/A

Restoring fluid levels N/A
devices of the machine N/A
Other tasks N/A
Fault-finding/trouble-shooting Adjustments N/A
Hazards from electrical and Ensure machine is isolated from
pneumatic energy energy supplies before dismantling
Fault-finding N/A
Isolation and energy dissipation N/A
protective devices failure N/A
Machine could restart unexpectedly Ensure machine is isolated from
energy supplies before attempting to
Recovering from jam clear jam
Hazards from electrical and Ensure machine is isolated from
Repairing
Replacement of parts, components, Hazards from electrical and Ensure machine is isolated from
devices of the machine pneumatic energy energy supplies before dismantling
Rescue of trapped persons N/A
Resetting N/A
Verification of parts, components, N/A
Other tasks N/A
Dismantling and disabling Disconnection and energy dissipation Hazards from electrical and Ensure machine is isolated from
Dismantling N/A
Removal and disposal of spent fluids N/A

Check if safe for one person to lift
Lifting Discomfort, musculoskeletal disorder machine unassisted
Loading N/A
Packing N/A
Transportation N/A
Unloading N/A
Other tasks N/A
Hazardous events
Shape and/or superficial finishing Contact with rough surfaces See above
corners, protruding parts See above
Moving parts of the machine Contact with moving parts See above
Contact with rotating open ends N/A
Crushing or impact from cable drum
handled
if it works loose See above
parts of the machine See above
parts of the machine, tools, etc operation N/A
Pneumatic and hydraulic Displacement of moving elements See above
equipment Projection of high-pressure fluids See above
Uncontrolled movements See above
Electrical equipment Direct contact See above
Disruptive discharge See above
Electric arc N/A
Fire N/A
Indirect contact N/A
Short-circuit See above
parts of the machine or of a Crushing or impact from cable drum
workpiece clamped by the machine if it works loose See above
Failure to stop moving parts Machine could fail to stop if control
circuit is faulty

protective devices N/A
speed changes) N/A
Unintended/unexpected start-up Machine could start unexpectedly if
control circuit is faulty
control system N/A
physical factors (temperature, temperature N/A
environment) hazardous N/A
be hazardous See above
signals See above
can be hazardous See above
be hazardous N/A
Harsh environmental conditions N/A
Workstation and/or work process Excessive effort N/A
induced by the design) N/A
area N/A
Painful and/or tiring postures N/A
N/A
Other Other events N/A
ard.
m diameter.
dept (last
ned during

Action required

1 5 0.5 1 2.5 Negligible None 0 Negligible
8 5 2 1 80 High Fit interlocked guarding 0.033 5 2 1 0.33 Negligible
0.033 5 15 1 2.475 Negligible Include warning in 0.033 5 15 1 2.475 Negligible
instructions
0.033 5 0.5 1 0.0825 Negligible None 0 Negligible
8 5 0.5 1 20 Low, significant Fit interlocked guarding 0.033 5 2 1 0.33 Negligible
0.033 5 0.5 1 0.0825 Negligible Ensure instructions 0 Negligible
refer to secure
anchoring
0.033 5 15 2 4.95 Negligible Use proven 0 Negligible
components and best-
practice design
2 5 0.1 1 1 Negligible Use best-practice 0 Negligible
design (material choice
for pulleys); include
warning in instructions
0.033 5 0.5 1 0.0825 Negligible Use best-practice 0 Negligible
design
0.033 5 15 1 2.475 Negligible Use best-practice 0 Negligible
design
design
design
design
design
design

design
design
design
1 5 0.5 4 10 Low, significant Use sound meter to 0.033 5 0.5 4 0.33 Negligible
check noise levels. If
excessive, enclosure
gearmotor
0.033 0 0.5 0 0 Negligible None 0 Negligible
0.033 0 0.5 0 0 Negligible None 0 Negligible

Action required

0.033 0.5 2 1 0.033 Negligible Ergonomic assessment 0 Negligible
0 Negligible None 0 Negligible

0.033 0.5 6 1 0.099 Negligible Use good working 0 Negligible
practices
0.033 0.5 15 1 0.2475 Negligible Use good working 0 Negligible
practices
0.033 0.5 2 1 0.033 Negligible Supply machine with 0 Negligible
regulator turned down
to minimum; include
warning in instructions

2 5 2 1 20 Low, significant Install interlocked 0.033 5 2 1 0.33 Negligible

guarding
2 0.5 15 1 15 Low, significant Warnings on machine 0.033 0.5 15 1 0.2475 Negligible
and in instructions;
competence of
technician
2 1 2 1 4 Negligible Warnings on machine 0 Negligible
and in instructions

competence of
technician
0 Negligible competence of 0 Negligible
0 Negligible technician 0 Negligible
competence of
technician
0.033 0.5 2 1 0.033 Negligible Ergonomic assessment 0 Negligible

Action required

0.033 5 2 1 0.33 Negligible Design control circuits 0 Negligible

to appropriate
standards
Action required
None
None
None
None
None
None
Action required
None
None
None
None
None
Action required

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www.machinesafety.co.uk info@machinesafety.co.

DPH (Degree of Possible Harm) NP (Number of Persons at risk)

Source: Pilz Guide to Machinery Safety, 6th Edition

Machines requiring action

Type or group of Potential

Exhaust system Discomfort

High-speed gas leak Discomfort

Manufacturing process (eg stamping, Discomfort

Moving parts Discomfort

Scraping surfaces Discomfort

Unbalanced rotating parts Discomfort

Whistling pneumatics Discomfort

Worn parts Discomfort

Hazardous situations (tasks)

Restoring fluid levels

Origin related to Hazardous event Consequences Comments

Shape and/or superficial finishing Contact with rough surfaces

Other Other events

LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

Type or group of Potential

Exhaust system Discomfort

High-speed gas leak Discomfort

Manufacturing process (eg stamping, Discomfort

Moving parts Discomfort

Scraping surfaces Discomfort

Unbalanced rotating parts Discomfort

Whistling pneumatics Discomfort

Worn parts Discomfort

Hazardous situations (tasks)

Restoring fluid levels

Origin related to Hazardous event Consequences Comments

Shape and/or superficial finishing Contact with rough surfaces

Other Other events

LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

Type or group of Potential

Static charge could build up where

Exhaust system Discomfort N/A

Manufacturing process (eg stamping, Discomfort N/A

Moving parts Discomfort

Only source of significant noise is

Hazardous situations (tasks)

Removal and disposal of spent fluids N/A

Removal and disposal of spent fluids N/A

Origin related to Hazardous event Consequences Comments

Machine action resulting from

Initial assessment Re-assessment after taking action

LO FE DPH NP HRN Risk level LO FE DPH NP HRN Risk level

0.033 5 0.5 1 0.0825 Negligible None 0 Negligible

8 5 2 1 80 High Fit interlocked guarding 0.033 5 2 1 0.33 Negligible

1.5 5 0.5 1 3.75 Negligible None 0 Negligible

8 5 0.5 1 20 Low, significant Fit interlocked guarding 0.033 5 2 1 0.33 Negligible

0.033 5 0.5 1 0.0825 Negligible Use best-practice 0 Negligible

0.033 5 0.5 4 0.33 Negligible None 0 Negligible

0.033 5 0.5 4 0.33 Negligible None 0 Negligible

0.033 5 0.5 1 0.0825 Negligible None 0 Negligible