Machinery Risk Assessment

A risk assessment is a careful look at your machines. You check what could hurt people and how likely it is to happen. You then decide on the best ways to stop those injuries. Think of it like a safety checkup for your equipment.

Why You Need to Check Your Machines

There are three big reasons to do these checks:

• To Save Lives: It prevents cuts, burns, and other bad injuries.
• To Follow the Law: Rules like OSHA and ISO 12100 say you must keep machines safe.
• To Save Money: Safe machines don’t break as often, and you avoid expensive fines.

The 5 Simple Steps of Risk Assessment

Step 1: Find the Hazards

Walk around your machines. Look for things that can pinch, cut, or crush. Check for hot parts, loud noises, or flying sparks. Ask the workers what scares them or what has almost hurt them before.

Step 2: Decide Who Might Get Hurt

Think about everyone who goes near the machine. This includes:

• Regular operators.
• Cleaning crews.
• Maintenance workers who fix the machine.
• Visitors walking past.

Step 3: Evaluate the Risk

For every hazard you found, ask two questions:

1. How bad would the injury be? (A small scratch or a broken bone?)
2. How likely is it to happen? (Does it happen every day or once a year?)

Step 4: Record Your Findings

Write down what you found. Put it in a simple list or a digital file. List the danger, who is at risk, and what you will do to fix it. This is your “Safety Paperwork.”

Step 5: Review and Update Regularly

Machines change over time. Parts get old, or you might move the machine to a new spot. Check your assessment every year or whenever you make a big change.

Modern Trends in Machine Safety

Digital Twins and AI Monitoring

In 2025, many companies use Digital Twins. This is a computer version of your real machine. The computer watches the machine in real-time. If it sees a part getting too hot or vibrating too much, it sends a warning to your phone. Artificial Intelligence (AI) can even predict when a machine might become dangerous before it actually breaks.

How to Lower the Risk (The Hierarchy of Control)

When you find a danger, use these steps in order. Start at the top because it is the most effective.

1. Elimination: Get rid of the danger completely. (Example: Use a machine that doesn’t need a blade.)
2. Substitution: Replace a dangerous part with a safer one. (Example: Use a quieter motor.)
3. Engineering Controls: Put a physical barrier between the person and the danger. (Example: Add a metal guard over a spinning wheel.)
4. Administrative Controls: Change how people work. (Example: Put up warning signs or train workers better.)
5. Personal Protective Equipment (PPE): Give workers gear to wear. (Example: Safety glasses, gloves, or earplugs.) Note: This is the last resort!

When Should You Do a New Assessment?

You should not just do a risk assessment once and forget it. Do a new one if:

• You buy a new machine.
• A worker gets hurt or has a “near miss.”
• You change the way the machine is used.
• The government changes the safety laws.

Conclusion

A machinery risk assessment is not just about paperwork. It is about making sure every worker goes home safe at the end of the day. By following these five steps and staying up to date with new tech like AI, you can make your workplace a much better place to be.