Technical Report - 10 - 38711

Scientific Technical Report
Risk Assessment
Machine 10 - 38711
Document N 155/2017
Gravata, September 2017
Antnio Bastos St, 32 - Cachoeirinha-RS - Phone: (51) 3439.2687 - e-mail: payback@payback.net.br - www.payback.net.br
Scientific Technical Report NR12
Document N 155/2017
Customer Information:
Company: Embraer/Laselec
Address: Presidente Dutra Highway, km 134.
City: So Paulo, SP
CNPJ:
CNAE:
Telephone:
Machinery Information:
Machine: Machine 10 - 38711

Number: 38711
Manufacturer: Laselec
Process: Laser wire marking
N of Operators: 1 operator
Service Provider Information:
Company: Payback Solues Em Segurana e Energia.

Developed by: Kelvim Reis dos Santos
Reviewed by: Guilherme Assis
Officer: Guilherme Assis
Contractor: Laselec
Date: 15/09/2017
Document Protected by Intellectual Property Law, All rights reserved to PAYBACK
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Document N 155/2017
TABLE OF CONTENTS
1. OBJECTIVES: ............................................................................. 5
2. LIMITATIONS: ........................................................................... 6
3. RISK ASSESSMENT METHODOLOGY ........................................... 7
3.1 Quantitative Method - HRN: ............................................................................. 8
3.2 Determination of the Safety Level to be adopted: ........................................... 11
4. MACHINERY IDENTIFICATION: ................................................ 13
4.1 Machinery General View: ................................................................................ 13
5. DETERMINATION OF THE LIMITS OF THE MACHINE*: ............. 14
5.1 Machinery Life Phases: ................................................................................... 14
5.2 Machinery Correct usage: ................................................................................ 14
5.3 Misuse Consequences: ..................................................................................... 14
6. MACHINERY DETECTED RISKS ESTIMATION: ........................... 15
6.1 Risk 1: Multi-spool Dereeler Monitored Movable Guard: ........................... 16
6.2 Risk 2: Multi-spool Dereeler Fixed Guard: .................................................. 17
6.3 Risk 3: Multi-spool Dereeler Casters: .......................................................... 18
6.4 Risk 4: Front Panel Monitored Movable Guard: .......................................... 19
6.5 Risk 5: Front Panel Translation of Information: ........................................... 20
6.6 Risk 6: Safety Reset Push-button: ................................................................... 21
7. OTHER RISKS........................................................................... 22
7.1 Electrical risks of the Facilities:....................................................................... 22
7.2 Ergonomic risks: .............................................................................................. 22
7.3 Chemical risks: ................................................................................................ 22
7.4 Biological risks: ............................................................................................... 22
7.5 Physical risks that are not present in this study: .............................................. 22
8. UTILIZED STANDARDS: ........................................................... 23
9. CONSIDERATIONS: .................................................................. 24
10. CONCLUSION: .......................................................................... 25
11. APPENDICES: ........................................................................... 26
11.1 Risks Matrix:.................................................................................................... 26
11.2 Chart HRN Before Safety Implementation:............................................... 27
11.3 Chart HRN After Safety Implementation: ................................................. 28
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Document N 155/2017
FIGURES:
Figure 1 Risk Assessment Simplified Flowchart - NBR 12100 ............................ 7

Figure 2 Tool for the determination of Category according to NBR 14153 ......... 11
Figure 3 Tool for PLr determination ............................................................. 11
Figure 4 Machinery General View ................................................................ 13
TABLES:
Table 1 Likelihood of Occurrence .................................................................. 9

Table 2 Frequency of Exposure..................................................................... 9
Table 3 Degree of Possible Harm .................................................................. 9
Table 4 Number of Person at risk ................................................................ 10
Table 5 Risk Classification ......................................................................... 10
Table 6 Current HRN - No Safety Implementation ......................................... 27
Table 7 - HRN After Safety Implementation .................................................... 28
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1. Objectives:
Mapping, identifying and quantifying risks based on the current machine control
systems, considering constructive aspects and relevant standards including NR 12 of
Regulatory Standards 3.214 / 77 and Law 6.514 / 77 of the Ministry of Labor and
Employment, Brazilian Standards NBRs and international standards when necessary.
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2. Limitations:
It is included in this Risk Assessment, the evaluation of the following activities:
Normal operation;
Cleaning;
Setup;
Adjustment;
Maintenance operations that require a reduced safety level.
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3. Risk Assessment Methodology

According to NBR ISO 12100 - Safety of machinery - General principles for design -
Risk assessment and risk reduction, Risk Assessment consists of a series of logical steps
that systematically allow the examination of the hazards associated with machines or
equipment.
Risk Assessment is followed, when necessary, by the Risk Reduction Analysis (as
shown in the flowchart shown in figure 1). When this process is repeated, an interactive
process occurs to mitigate hazards as much as possible and to implement safety measures
according to the state of the art.
Figure 1 Risk Assessment Simplified Flowchart - NBR 12100
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3.1 Quantitative Method - HRN:
Risk assessment is based on critical decisions. Such decisions shall be based on

qualitative methods, supplemented as far as possible by quantitative methods. Quantitative
methods are particularly appropriate, when the severity and predictable extent of harm are
high.
Therefore we chose to use the HRN methodology, which is the quantitative estimation
of the risk according to ISO 12100, which is determined by the evaluation of the
operational, electrical, and mechanical aspects and by the influence of the factors of the
manufacturing environment to which the object of the risks is being evaluated, therefore
engineering practices should be complemented by the thorough technical knowledge of
machines and devices, after thorough field analysis, it can be determined the degree of risk
of each point by multiplying numerical values assigned to descriptive phases according to
the following formula:
HRN = LO x FE x DPH x NP,
The values of each of the factors below shall be evaluated:
Likelihood of Occurrence (LO);

Frequency of Exposure (FE);
Degree of Possible Harm (DPH);
Number of Person at risk (NP);
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3.1.1 Likelihood of Occurrence (LO):
Table 1 Likelihood of Occurrence
3.1.2 Frequency of Exposure (FE):
Table 2 Frequency of Exposure
3.1.3 Degree of Possible Harm (DPH):
Table 3 Degree of Possible Harm
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3.1.4 Number of Person at risk (NP):
Table 4 Number of Person at risk
3.1.5 Result of Risk Classification:
HRN Classification
0 - 0,99 Negligible
1 - 4,99 Very Low
5 - 9,99 Low
10 - 49,99 Significant
50 - 99,99 High
100 - 499,99 Very High
500 - 999,99 Extreme
Over 1000 Unacceptable
Table 5 Risk Classification
Actions shall be taken prioritizing the highest risks detected, risks classified from
"Negligible" to "Low" do not require intervention, and only the procedures to control the
existing residual risk are required. Risks classified from "Significant" to "Unacceptable" shall
be provided with guards or safety equipment considering the required category to seek
near-zero HRN values.
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3.2 Determination of the Safety Level to be adopted:
When the safety solution requires a control system (interface + sensors + actuators),
it is necessary to observe the safety category necessary to control the risk, so it is
necessary to use the same adopted parameters of Frequency, Exposure and Probability of
Harm Avoidance.
The determination of the safety level is provided in NBR 14153, which is the Brazilian
standard in this issue and presents the following tool for determining the safety category to
be adopted:
Figure 2 Tool for the determination of Category according to NBR 14153
In order to align the new existing technologies with the updated risk analysis
demands, we chose to include in the Risk Assessment the methodology for determining the
requirements of a safety system according to ISO 13849-1 - PLr method, which covers all
electronic safety systems available and presents the possibility of analyzing system
performance and determining specific risk categories for each type of component. This tool
is more complex and requires a greater number of information and technical knowledge of
design and system specification. The picture below presents the tool for determining the
PLr (required) as determined in ISO 13849-1.
Figure 3 Tool for PLr determination
The purpose of this Risk Assessment is only to establish the required Performance
Level (PLr), so it is possible (when necessary) to use this parameter, which is already
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Document N 155/2017
available for several safety equipment manufacturers, to define which devices should be
purchased.
It is important to note that the regulatory requirements when redundancy, duplicity
and required category in type-C standards and NR12 takes precedence over the above
standards.
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4. Machinery Identification:
4.1 Machinery General View:
Figure 4 Machinery General View
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5. Determination of the limits of the machine*:

* NBR 12100, Item 5.3
5.1 Machinery Life Phases:
This study analyzes only the machine utilization phase, considering the following
aspects:
- Regulation, training, programming or change of the manufacturing process;
- Running;
- Operation;
- Cleaning;
- Failure or breakdown research;
- Maintenance.
5.2 Machinery Correct usage:
The machine has been set up to perform the laser marking of the cables, so any
changes in the process must be carefully analyzed in order to investigate whether this
change could cause additional risks not predicted by the manufacturer.
5.3 Misuse Consequences:
The operator must place the cable coils next to the multi-spool dereeler in order to
start the automatic cable marking process. Therefore, any other use than that specified by
the manufacturer may result in an unpredicted risk.
Disabling any item of the safety system is also characterized as incorrect use of the
equipment as this intervention is not determined by the machine manufacturer.
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6. Machinery Detected Risks Estimation:
In the subitems below we observe and analyze in detail each point of the machine in
a probabilistic way in order to measure the risk before the safety implementation and
projecting the risk after the implementation, thus we have a measurement of the achieved
results and the existent residual risks.
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6.1 Risk 1: Multi-spool Dereeler Monitored Movable Guard:
RISK ASSESSMENT
Risk Description:
The current movable guard is monitored by a tongue operated safety switch, which does not comply the
safety performance with the combination of components from different technologies.
Likelihood of Occurrence
2 - Possible RISK LEVEL - HRN = 40
(LO):
Frequency of Exposure (FE): 5 - Constantly
Degree of Possible Harm 4- Loss of limb/eye/serious

Risk Classification: Significant
(DPH): illness of a temporary nature
Number of Persons at risk
1 - 1-2 persons
(NP):
Crushing; Cutting or Severing; Drawing-in or Trapping; Entanglement; Friction or Abrasion;

DETECTED HAZARDS
Impact.
EQUIPMENT PICTURES
PICTURE 1 PICTURE 2
RISK REDUCTION ANALYSIS

Safety Integrity Level for the Required System:
Severity of injury (S) S2 - Severe injury
Frequency of Exposure (F) F2 - Frequent or long duration
Possibility of Avoidance (P) P1 - Possible
Category: 3 and Performance Level (PLr): d
Description for the Proposed Solution
Provide the installation of a magnetic safety switch, in addition to the existing tongue operated safety
switch. The entire system must be interconnected to a category 3 safety interface and it needs to have a
safety reset push-button positioned in a place that allows a clear and unobstructed view of the whole area.
0,1 - Almost impossible RISK LEVEL - HRN= 2
(LO):
Risk Classification: Very Low
1 - 1-2 persons
(NP):
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6.2 Risk 2: Multi-spool Dereeler Fixed Guard:
RISK ASSESSMENT
Risk Description:
Currently there is an opening in the passage of the wire to the multi-spool dereeler, which allows free
access of upper limbs to the moving parts, therefore it does not meet the NR12 regulatory requirements.
5 - Even chance RISK LEVEL - HRN = 50
(LO):
Degree of Possible Harm 2 - Break of a major bone or

Risk Classification: High
(DPH): minor illness (permanent)
1 - 1-2 persons
(NP):
DETECTED HAZARDS Drawing-in or Trapping; Entanglement; Impact.
EQUIPMENT PICTURES
PICTURE 1 PICTURE 2

Severity of injury (S) Not Applicable
Frequency of Exposure (F) Not Applicable
Possibility of Avoidance (P) Not Applicable
Category: Not Applicable and Performance Level (PLr): Not Applicable
Provide the installation of a complement to the existing fixed guard, preventing access to the moving parts
of the equipment. The guard must be made of polycarbonate and fixed with screws that allow their removal
only with the use of tools. It shall also be considered the installation of a tunnel from one machine to another,
preventing any contact during the cable transfer.
0,5 - Highly unlikely RISK LEVEL - HRN= 1,5
(LO):
Frequency of Exposure (FE): 1,5 - Weekly
Degree of Possible Harm 2 - Break of a major bone or
(DPH): minor illness (permanent)
1 - 1-2 persons
(NP):
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6.3 Risk 3: Multi-spool Dereeler Casters:
RISK ASSESSMENT
Risk Description:
The current casters do not have brakes that maintain the machine stationary and steady, thus failing to meet
the item 12.12 of NR12.
5 - Even chance RISK LEVEL - HRN = 25
(LO):
Degree of Possible Harm 1 - Break of a minor bone or
(DPH): minor illness (temporary)
1 - 1-2 persons
(NP):
DETECTED HAZARDS Crushing; Drawing-in or Trapping; Impact.
EQUIPMENT PICTURES
PICTURE 1 PICTURE 2

Severity of injury (S) Not Applicable
According to the regulatory requirements of NR12, at least two casters of a moveable machine shall have
brakes.
1 - Unlikely RISK LEVEL - HRN= 5
(LO):
Degree of Possible Harm 1 - Break of minor bone or
Risk Classification: Low
(DPH): minor illness (temporary)
1 - 1-2 persons
(NP):
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Document N 155/2017
6.4 Risk 4: Front Panel Monitored Movable Guard:
RISK ASSESSMENT
Risk Description:
The current movable guard is monitored by a tongue operated safety switch, which does not comply the
safety performance with the combination of components from different technologies.
(LO):
1 - 1-2 persons
(NP):
DETECTED HAZARDS Crushing; Drawing-in or Trapping; Impact.
EQUIPMENT PICTURES
PICTURE 1 PICTURE 2

Provide the installation of a magnetic safety switch, in addition to the existing tongue operated safety
switch. The entire system must be interconnected to a category 3 safety interface and it needs to have a
safety reset push-button positioned in a place that allows a clear and unobstructed view of the whole area..
(LO):
1 - 1-2 persons
(NP):
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6.5 Risk 5: Front Panel Translation of Information:
RISK ASSESSMENT
Risk Description:
Currently the information of the machine functions on the HMI is in English, thus failing to meet the NR12
regulatory requirements, item 12.119.
1 - Unlikely RISK LEVEL - HRN = 0,5
(LO):
Degree of Possible Harm
0,1 - Scratch or bruise Risk Classification: Negligible
(DPH):
1 - 1-2 persons
(NP):

DETECTED HAZARDS
Impact.
EQUIPMENT PICTURES
PICTURE 1 PICTURE 2

Description for the Proposed Solution Not Applicable
Descrio da Soluo Proposta
Provide the translation to Brazilian Portuguese of all the information of the HMI, which represents the
functions of each device of the machine, in order to meet the item 12.119 regulatory requirements.
0,5 - Highly unlikely RISK LEVEL - HRN= 0,25
(LO):
Degree of Possible Harm
0,1 - Scratch or bruise Risk Classification: Negligible
(DPH):
1 - 1-2 persons
(NP):
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6.6 Risk 6: Safety Reset Push-button:
RISK ASSESSMENT
Risk Description:
Currently the machine does not have a safety reset push-button related to the emergency system, thus it
does not comply with NR12 regulatory requirements.
(LO):
1 - 1-2 persons
(NP):

DETECTED HAZARDS
Impact.
EQUIPMENT PICTURES
PICTURE 1 PICTURE 2

The equipment safety system must have a safety reset push-button for the whole system, to be performed
only after the correction of the event that caused the emergency stop actuation, in order to comply with
NR12 regulatory requirements, item 12.63.
(LO):
1 - 1-2 persons
(NP):
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7. Other Risks
7.1 Electrical risks of the Facilities:
They are not part of this study
7.2 Ergonomic risks:
7.3 Chemical risks:
7.4 Biological risks:
7.5 Physical risks that are not present in this study:
Thermal stress
Noise
Radiation
Pressure
Vibration
Humidity
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8. Utilized Standards:
NR 10: segurana em instalaes e servios em eletricidade. Braslia, 2004 e

portaria n 484, 2005.
NR 12: mquinas e equipamentos. Braslia e portaria MTb n. 873, de 06 de
julho de 2017.
ABNT NBR ISO 12100 - Segurana de mquinas - Princpios gerais de projeto -
Apreciao e reduo de riscos. Rio de Janeiro, 17 de Dezembro de 2013.
NBR 14153: segurana de mquinas: partes de sistemas de comando
relacionados segurana: princpios gerais para projeto. Rio de Janeiro, 1998.
ISO 14121-1: Safety of Machinery: risk assessment. Geneva, 2007.
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9. Considerations:
Operators should be trained and aware of the risks and control measures adopted up
to this date.
All design and / or modification in the machine must be developed or supervised by a
legally qualified professional with ART collection.
In addition, systems implemented by the company must be maintained and verified
by operators and maintenance staff to ensure their efficiency as provided in NR12.
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10. Conclusion:
We conclude that the machine 10 - 38711 presents a considerable level of items to

be adjusted according to NR12. We suggest the adequacy to the points indicated in this
document. The systems must be defined observing the safety regulations through a project
developed by a legally qualified professional.
The Risk Reduction Analysis in this document is not the unique solution, and the
professional responsible for the project design can suggest new solutions as long as they
meet the regulatory requirements and mitigate the risk in question.
This report was based on field inspections performed by Payback in August 2017, any
changes in the machine that implies in an increase in the risks already evaluated will
require a new study.
28-page document printed on one side only, duly initialed with this signed copy.
Cachoeirinha, September 15th, 2017
Developed by: Approved by:
Kelvim Reis dos Santos Guilherme Assis

Projects Technician Project Coordinator
Payback Solues Em Segurana e Energia. Payback Solues Em Segurana e Energia.
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Document N 155/2017
11. Appendices:
11.1 Risks Matrix:
Risks Matrix HRN

Mquina 10 - 38711
Number Description Current HRN Cat/ PLr Projected HRN Reduction
Risk 1 Multi-spool Dereeler Monitored Movable Guard. 40 3, d 2 95%

Risk 2 Multi-spool Dereeler Fixed Guard. 50 NA 1,5 97%
Risk 3 Multi-spool Dereeler Casters. 25 NA 5 80%
Risk 4 Front Panel Monitored Movable Guard. 40 3, d 2 95%
Risk 5 Front Panel Translation of Information. 0,5 NA 0,25 50%
Risk 6 Safety Reset Push-button. 40 3, d 2 95%
Current Situation Proposed Situation 85%
Machinery Total Risk: 195,5 Machinery Total Risk: 12,75

Machinery Highest Risk: 50 Machinery Highest Risk: 5
Average Risk Reduction: 85%
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11.2 Chart HRN Before Safety Implementation:
CURRENT DEMONSTRATIVE CHART

Machine 10 - 38711
Current HRN - No Safety Implementation

13
140 14
15
120 16
17
100 18
19
80
20
21
60
22
50 23
40 24 40 40
40
25
20
0,5
0
Risk 1
Risk 2
Risk 3
Risk 4
Risk 5
Risk 6
Negligible Very Low Low Significant High Very High Extreme Unacceptable
Table 6 Current HRN - No Safety Implementation
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11.3 Chart HRN After Safety Implementation:
PROJECTED DEMONSTRATIVE CHART

Machine 10 - 38711
HRN - With Safety Implementation

13
14
15
16
17
18
19
20
21
22 5
23
2 1,5 2 2
24 0,25
0
Risk 1
Risk 2
Risk 3
Risk 4
Risk 5
Risk 6
Negligible Very Low Low Significant High Very High
Table 7 - HRN After Safety Implementation
28

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Scientific Technical Report

Gravata, September 2017

Machine: Machine 10 - 38711

Service Provider Information:

Company: Payback Solues Em Segurana e Energia.

Document Protected by Intellectual Property Law, All rights reserved to PAYBACK

Document Protected by Intellectual Property Law, All rights reserved to PAYBACK

Figure 1 Risk Assessment Simplified Flowchart - NBR 12100 ............................ 7

Table 1 Likelihood of Occurrence .................................................................. 9

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It is included in this Risk Assessment, the evaluation of the following activities:

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3. Risk Assessment Methodology

Figure 1 Risk Assessment Simplified Flowchart - NBR 12100

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3.1 Quantitative Method - HRN:

Risk assessment is based on critical decisions. Such decisions shall be based on

HRN = LO x FE x DPH x NP,

The values of each of the factors below shall be evaluated:

Likelihood of Occurrence (LO);

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3.1.1 Likelihood of Occurrence (LO):

Table 1 Likelihood of Occurrence

3.1.2 Frequency of Exposure (FE):

Table 2 Frequency of Exposure

3.1.3 Degree of Possible Harm (DPH):

Table 3 Degree of Possible Harm

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3.1.4 Number of Person at risk (NP):

Table 4 Number of Person at risk

3.1.5 Result of Risk Classification:

Table 5 Risk Classification

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3.2 Determination of the Safety Level to be adopted:

Figure 2 Tool for the determination of Category according to NBR 14153

Figure 3 Tool for PLr determination

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4.1 Machinery General View:

Figure 4 Machinery General View

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5. Determination of the limits of the machine*:

5.2 Machinery Correct usage:

5.3 Misuse Consequences:

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6. Machinery Detected Risks Estimation:

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6.1 Risk 1: Multi-spool Dereeler Monitored Movable Guard:

Frequency of Exposure (FE): 5 - Constantly

Degree of Possible Harm 4- Loss of limb/eye/serious

Crushing; Cutting or Severing; Drawing-in or Trapping; Entanglement; Friction or Abrasion;

RISK REDUCTION ANALYSIS

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6.2 Risk 2: Multi-spool Dereeler Fixed Guard:

Frequency of Exposure (FE): 5 - Constantly

Degree of Possible Harm 2 - Break of a major bone or

DETECTED HAZARDS Drawing-in or Trapping; Entanglement; Impact.

RISK REDUCTION ANALYSIS

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6.3 Risk 3: Multi-spool Dereeler Casters:

DETECTED HAZARDS Crushing; Drawing-in or Trapping; Impact.

RISK REDUCTION ANALYSIS

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6.4 Risk 4: Front Panel Monitored Movable Guard: