Example of how to perform the risk

assessment for a product covered by

Machinery directive

Gran Lundmark
 Machinery Directive 2006/42/EC,
ANNEX I
Essential health and safety requirements relating to the
design and construction of machinery

GENERAL PRINCIPLES

The manufacturer must ensure that a risk assessment is carried out

and determine the health and safety requirements which apply.

The machinery must then be designed and constructed taking into

account the results of the risk assessment.
 EN ISO 14121-1, Safety of machinery
Risk assessment Part 1:Principles
2006/42/EC, ANNEX I

Iterative process of risk

assessment and risk reduction:

determine the limits of the

machinery

identify the hazards

estimate the risks

evaluate the risks,

eliminate the hazards or

reduce the risks
 Determination of limits of machinery
Use limits.
Example of aspects to take into account:
Different operating modes and
intervention procedures
Intended use and user population
(industrial domestic, sex, age, limiting
physical abilities etc.)
Anticipated levels of training,
experience or ability of users
Exposure of other persons
 Determination of limits of machinery
Space limits.
Example of aspects to take into account:
Range of movement
Space requirements for persons
Human interaction
Machine-power supply interface
 Determination of limits of machinery
Time limits.
Example of aspects to take into account:
Life limit of machinery and components
Recommended service intervals

Other limits.
Examples
Environmental limits (min max
temperature, indoors outdoors, dry wet,
etc.)
Housekeeping level of cleanliness
required
Properties of processed materials
 Hazard identification
Important to regard hazards during all
phases of the machine life cycle
(e.g. transport, assembly and installation,
commissioning, use, de-commissioning,
dismantling and disposal).

Task identification (setting, start-up, feeding,

stop, emergency stop, operator intervention,
cleaning etc.)

Various methods for structured hazard

identification are available.

Two basic approaches.

 Hazard identification
Top-down approach:
Starts with a check-list of potential
consequences and establishes what could
cause harm.

E.g. Potential consequence = crushing

What could cause harm = moving
elements, loss of stability, falling objects etc.

Disadvantage:
Checklists are not exhaustive and requires
experience and creative thinking to see
beyond the list.
 Hazard identification
Bottom-up approach:
Starts with examining all the hazards and
considering all possible ways that something
can go wrong. Is more comprehensive and
thorough.

E.g. Origin of hazard = moving element nr 1.

Potential consequences = crushing, cutting,
abrasion, impact, shearing etc.

Disadvantage:
More time-consuming
 Risk estimation
Risk is a function of
severity of harm and
probability of occurrence.

The probability of occurrence is a

function of
the exposure of persons to the hazard
the occurrence of a hazardous event
the technical and human possibilities of
avoiding or limiting the harm
 Risk estimation
Risk estimation tools

Available tools normally uses

a risk matrix
 Risk estimation
Risk estimation tools

Available tools normally uses

a risk matrix
a risk graph
 Risk estimation
Risk estimation tools

Available tools normally uses

a risk matrix
a risk graph
 Risk estimation
Risk estimation tools

Available tools normally uses

a risk matrix
a risk graph
numerical scoring
quantified risk estimation
combinations of the above
 Risk evaluation
The objectives of risk evaluation are
to decide which hazardous situations
require further risk reduction, and
to determine whether required risk
reduction has been achieved without
introducing further hazards or increased
other risks
 Risk reduction
Risk reduction is achieved by
implementing protective measures.
Priority order of protective measures:
1.Elimination of hazard
2.Elimination of hazardous situation,
i.e. limit exposure
3.Elimination of possible hazardous
events
4.Implementation of means to avoid
harm
 Example

Use limits:
..
.
Occasional need for intervention
procedure of the operator by
malfunction of machine

 Example

Hazard identification:
 Example

Risk estimation
Crushing
 Example

Risk evaluation: Risk reduction necessary

Crushing
 Example

Risk reduction
1. Elimination of hazard 1. Increase distance
2. Elimination of hazardous 2. ..
situation, i.e. limit 3. ..
exposure
3. Elimination of possible
hazardous events
4. Implementation of means
to avoid harm
 Example

a
Risk reduction
Action: Extend frame of machine to implement a safety gap
between frame and moving part.
Specification according to EN 349 Safety of machinery
Minimum gaps to avoid crushing of parts of the human body.
 Example

a
Risk estimation
Crushing
 Example

Risk evaluation: No further risk reduction required

Crushing
Further guidance can be found in:

EN ISO 14121-1
Safety of machinery Risk assessment Part
1: Principles

ISO/TR 14121-2
Safety of machinery Risk assessment Part
2: Practical guidance and examples of
methods