Risk Assessment Calculator1

www.machinesafety.co.
uk
guards@procterbedwas.co.uk
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How to use the Procter Risk Assessment Calculator
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
Guarding 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.
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.
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.
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.
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.
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 Guarding - the UK's leading supplier of bespoke and modular machine guarding
Procter Machine Guarding, 11 Pantglas Industrial Estate, Bedwas, Caerphilly, CF83 8XD, UK
Tel: +44 (0)29 2085 5758. Fax: +44 (0)29 2088 7005
www.machinesafety.co.uk
guards@procterbedwas.co.uk
LO (Likelihood of Occurrence) FE (Frequency of Exposure)
0.033 Almost impossible Only in extreme circumstances 0.5 Annually
1 Highly unlikely Though conceivable 1 Monthly
1.5 Unlikely But could occur 1.5 Weekly
2 Possible But unusual 2.5 Daily
5 Even chance Could happen 4 Hourly
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
HRN Risk
0-5 Negligible
5-50 Low, significant
50-500 High
Over 500 Unacceptable
HRN = LO x FE x DPH x NP
Company name:
Company address:
Assessment reference:
Assessment carried out by:
Assessment date:
Assessment checked by:
Assessment approved by:
Worksheet reference: Machine reference:
Machines requiring action
Action required:
Machines requiring action
Type of machine:
Machine location:
Machine description:
Machine manufacturer:
Machine model:
Machine serial number:
Modifications from 'as-supplied':
Energy sources:
Energy source ratings:
Safety measures:
Assessment date:
Mechanical hazards
Angular parts
Acceleration/deceleration
Type or group of
hazard
Origin
Kinetic energy
Cutting parts
Elastic elements
Falling objects
Approach of a moving element to a
fixed part
Gravity
Stored energy
Height from the ground
High pressure
Machinery mobility
Moving elements
Rotating elements
Surface finish (rough or slippery)
Sharp edges
Instability
Vacuum
Other
Electrical hazards Arc
Electromagnetic phenomena
Electrostatic phenomena
Live parts
Overload
Short-circuit
Thermal radiation
Other
Thermal hazards Explosion
Insufficient distance from live parts
under high voltage
Parts becoming live under fault
conditions
Flame
Radiation from heat sources
Other
Noise hazards Cavitation phenomena
Exhaust system
High-speed gas leak
Objects or materials with a high or
low temperature
Moving parts
Scraping surfaces
Unbalanced rotating parts
Whistling pneumatics
Manufacturing process (eg stamping,
pressing, grinding)
Worn parts
Other
Vibration hazards Cavitation phenomena
Misalignment of moving parts
Mobile equipment
Scraping surfaces
Vibrating equipment
Worn parts
Other
Radiation hazards Ionising radiation source
Other
Material/substance hazards Aerosol
Combustible
Low-frequency electromagnetic
radiation
Optical radiation (infrared, visible
and ultraviolet), including laser
Radio frequency electromagnetic
radiation
Biological and microbiological (viral
or bacterial) agent
Dust
Explosive
Fibre
Flammable
Fluid
Fume
Gas
Mist
Oxidiser
Other
Ergonomic hazards Access
Effort
Design, location or identification of
control devices
Design or location of indicators and
visual display units
Local lighting
Mental overload or underload
Posture
Repetitive activity
Visibility
Other
Dust and fog
Electromagnetic disturbance
Flicker, dazzling, shadow,
stroboscopic effect
Hazards associated with the
environment in which the machine
is used
Lighting
Moisture
Pollution
Snow
Temperature
Water
Wind
Lack of oxygen
Other
Combined hazards eg repetitive activity + effort + high
environmental temperature
Transport Lifting
Loading
Packing
Transportation
Unloading
Unpacking
Other tasks
Assembly, installation and
commissioning
Preparations for installation (eg
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
and/or process changeover
Mounting or changing tools, tool-
setting
Adjustment and setting of protective
devices and other components
Hazardous situations (tasks)
Phase of machine
lifecycle
Tasks
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
Contact with rough surfaces
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
energy (gravity) of the machine,
parts of the machine, tools and
materials used, processed or
handled
Falling or ejection of objects
Stability of the machine and/or
parts of the machine
Loss of stability
Mechanical stiffness/strength of
parts of the machine, tools, etc
Deflection or break-up during
operation
Pneumatic and hydraulic Displacement of moving elements
Projection of high-pressure fluids
Uncontrolled movements
Electrical equipment Direct contact
Disruptive discharge
Electric arc
Fire
Indirect contact
Short-circuit
Shape and/or superficial finishing
of accessible parts of the machine
Origin related to Hazardous event
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
Contact with objects with high or low
temperature
Emission of a substance that can be
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
Excessive effort
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
Workstation and/or work process
design
Materials and substances or
physical factors (temperature,
noise, vibration, radiation and
environment)
Number of operatives:
Number of shifts per week:
Usage (hours per month):
Operating manuals:
Standard operating procedures:
Operatives' training record:
Warning signs:
Raw materials:
Maintenance manual:
Maintenance training record:
Access by untrained visitors:
LO FE DPH NP
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
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Potential
consequences
Comments
Initial assessment
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Other
Burn
Chemical effects
Effects on medical implants
Electrocution
Falling or being thrown
Fire
Projection of molten particles
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Other
Burn
Dehydration
Discomfort
Frostbite
Injuries from radiated heat
Scald
Burn
Dehydration
Discomfort
Frostbite
Scald
Burn
Dehydration
Discomfort
Frostbite
Scald
Burn
Dehydration
Discomfort
Frostbite
Scald
Other
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.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Other
Discomfort
Low-back disease
Neurological disorder
Osteo-articular disorder
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Other
Burn
Damage to eyes and skin
Effects on reproductive capability
Genetic mutation
Headache, insomnia, etc
Burn
Genetic mutation
Burn
Genetic mutation
Burn
Genetic mutation
Other
Breathing difficulties, suffocation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Other
Discomfort
Fatigue
Musculoskeletal disorder
Stress
Other (eg mechanical, electrical) as
a consequence of human error
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Other
Burn
Slight disease
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
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Other
eg dehydration, loss of awareness,
heat stroke
LO FE DPH NP
Initial assessment
Consequences Comments
LO FE DPH NP
Initial assessment
HRN Risk level LO FE DPH NP HRN Risk level
0 Negligible 0 Negligible
Initial assessment Re-assessment after taking action
Action required
Initial assessment
Action required
Re-assessment after taking action
Initial assessment
Action required
Action required
Action required
Action required
Type of machine:
Machine location:
Machine description:
Machine manufacturer:
Machine model:
Machine serial number:
Modifications from 'as-supplied':
Energy sources:
Energy source ratings:
Safety measures:
Assessment date:
Mechanical hazards
Angular parts
Kinetic energy
Type or group of
hazard
Origin
Cutting parts
Elastic elements
Falling objects
fixed part
Gravity
Stored energy
High pressure
Machinery mobility
Moving elements
Rotating elements
Sharp edges
Instability
Vacuum
Other
Live parts
Overload
Short-circuit
Thermal radiation
Other
under high voltage
conditions
Flame
Other
Exhaust system
High-speed gas leak
low temperature
Moving parts
Scraping surfaces
pressing, grinding)
Worn parts
Other
Mobile equipment
Scraping surfaces
Vibrating equipment
Worn parts
Other
Other
Combustible
radiation
or bacterial) agent
radiation
Dust
Explosive
Fibre
Flammable
Fluid
Fume
Gas
Mist
Oxidiser
Other
Effort
control devices
Local lighting
Posture
Repetitive activity
Visibility
Other
Dust and fog
stroboscopic effect
is used
Lighting
Moisture
Pollution
Snow
Temperature
Water
Wind
Lack of oxygen
Other
Transport Lifting
Loading
Packing
Transportation
Unloading
Unpacking
Other tasks
commissioning
Fixing, anchoring
components
Fencing
Testing
Demonstration
Other tasks
setting
Phase of machine
lifecycle
Tasks
travel limits)
material
Other tasks
material
Driving the machine
limits)
workpiece
Control/inspection
Supervision
Other tasks
Housekeeping
Lubrication
parts
Resetting
Other tasks
Fault-finding
Recovering from jam
Repairing
Resetting
Other tasks
dissipation
Dismantling
Lifting
Loading
Packing
Transportation
Unloading
Other tasks
Hazardous events
handled
Loss of stability
operation
Electric arc
Fire
Indirect contact
Short-circuit
protective devices
speed changes)
control system
temperature
hazardous
be hazardous
signals
can be hazardous
be hazardous
Excessive effort
area
Other Other events
environment)
design
Operating manuals:
Warning signs:
Raw materials:
Maintenance manual:
LO FE DPH NP
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Initial assessment
Potential
consequences
Comments
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Being run over
Being thrown
Crushing
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Other
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Burn
Chemical effects
Electrocution
Fire
Shock
Other
Burn
Dehydration
Discomfort
Frostbite
Scald
Burn
Dehydration
Discomfort
Frostbite
Scald
Burn
Dehydration
Discomfort
Frostbite
Scald
Burn
Dehydration
Discomfort
Frostbite
Scald
Other
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Discomfort
Loss of awareness
Loss of balance
Stress
Tinnitus
Tiredness
acoustic signals.
Other
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Discomfort
Low-back disease
Trauma of the spine
Vascular disorder
Other
Burn
Genetic mutation
Burn
Genetic mutation
Burn
Genetic mutation
Burn
Genetic mutation
Other
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Cancer
Corrosion
Explosion
Fire
Infection
Mutation
Poisoning
Sensitisation
Other
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Discomfort
Fatigue
Stress
Other
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Burn
Slight disease
Slipping or falling
Suffocation
the machine
Other
heat stroke
LO FE DPH NP
Initial assessment
LO FE DPH NP
Initial assessment
Action required
Initial assessment
Action required
Initial assessment
Action required
Action required
Action required
Action required
Assessment reference: 0101
Type of machine: Cable re-reeler
Machine location: Building 01, cable section
Machine description: Machine re-reels cable following
marking or measuring operations on
other machines.
Machine manufacturer: CableMagic
Machine model: CM01
Machine serial number: 0000123
Modifications from 'as-supplied': None
Energy sources: Electricity, compressed air
Energy source ratings: 240V AC; 6bar pressure
Safety measures: Emergency stop button connected to
safety relay - isolates power and
operates dump valve.
Assessment carried out by: A. Person
Assessment date: 14 December 2011
Assessment checked by: A. N. Other Person
Assessment approved by: A. Third Person
Mechanical hazards
Kinetic energy
Type or group of
hazard
Origin
Angular parts
Cutting parts
Elastic elements
fixed part
Falling objects
Gravity
Stored energy
High pressure
Machinery mobility
Moving elements
Rotating elements
Sharp edges
Instability
Vacuum
Other
Live parts
Overload
under high voltage
Short-circuit
Thermal radiation
Other
Flame
conditions
Other
Exhaust system
High-speed gas leak
low temperature
pressing, grinding)
Moving parts
Scraping surfaces
Worn parts
Other
Mobile equipment
Scraping surfaces
Vibrating equipment
Worn parts
Other
Other
Combustible
radiation
radiation
or bacterial) agent
Dust
Explosive
Fibre
Flammable
Fluid
Fume
Gas
Mist
Oxidiser
Other
control devices
Effort
Local lighting
Posture
Repetitive activity
Visibility
Other
Dust and fog
control devices
stroboscopic effect
is used
Lighting
Moisture
Pollution
Snow
Temperature
Water
Wind
Lack of oxygen
Other
Transport Lifting
Loading
Packing
Transportation
Unloading
Unpacking
Other tasks
commissioning
Fixing, anchoring
Phase of machine
lifecycle
Tasks
components
Fencing
Testing
Demonstration
Other tasks
setting
travel limits)
material
Other tasks
material
Driving the machine
limits)
workpiece
Control/inspection
Supervision
Other tasks
Housekeeping
Lubrication
parts
Resetting
Other tasks
Fault-finding
Recovering from jam
Repairing
Resetting
Other tasks
dissipation
Dismantling
Lifting
Loading
Packing
Transportation
Unloading
Other tasks
Hazardous events
handled
Loss of stability
operation
Electric arc
Fire
Indirect contact
Short-circuit
protective devices
speed changes)
control system
temperature
hazardous
be hazardous
environment)
signals
can be hazardous
be hazardous
Excessive effort
area
Other Other events
design
Operating manuals:
Warning signs:
Raw materials:
Maintenance manual:
LO FE DPH NP
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 run over
Being thrown
Crushing Rotating cable reel (approx 5kg, card
or plastic flanges, no sharp edges)
could become detached.
1 5 0.5 1
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
Yes, adjacent to machine.
Yes, held in HR file.
One, relating to pinch hazard.
1
5
35
Yes, as supplied
Electrical cable up to 3mm diameter.
Yes, held in maintenance dept (last
serviced 3 months ago).
Maintenance manager trained during
installation of machine.
Initial assessment
None
Potential
consequences
Comments
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
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
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
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
8 5 2 1
Entanglement N/A
Impact Pneumatic-actuated (10mm cylinder)
'dancing arm' could strike hand or
finger
8 5 2 1
Injection N/A
Shearing N/A
Suffocation N/A
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
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
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
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
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
0.033 5 15 1
Suffocation N/A
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
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
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.
1 5 0.5 1
Cutting or severing Rotating cable reel (card or plastic
flanges, no sharp edges, up to 100
rpm, max 250mm dia).
0.033 5 0.5 1
Drawing-in or trapping Nip point where cable is wound onto
reel
8 5 2 1
Entanglement Exposed end of shaft on which cable
reel is mounted
1.5 5 0.5 1
Friction or abrasion Rotating cable reel (card or plastic
flanges, no sharp edges, up to 100
rpm, max 250mm dia).
8 5 0.5 1
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
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
0.033 5 0.1 1
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
Being run over N/A
Being thrown N/A
Crushing N/A
Cutting or severing Potential for inadequately finished
cast, machined and other edges
0.5 5 0.1 1
Entanglement N/A
Impact N/A
Injection N/A
Shearing N/A
Suffocation N/A
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
0.033 5 0.5 1
Injection N/A
Shearing N/A
Suffocation N/A
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 N/A
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
Burn N/A
Effects on medical implants Potential for stray EMI 0.033 5 15 2
Electrocution N/A
Fire N/A
Shock N/A
Burn N/A
Electrocution N/A
Fire N/A
Shock
Static charge could build up where
cable passes over pulleys
2 5 0.1 1
Burn
All electrical components contained
within earthed metal machine casing
0.033 5 0.5 1
Electrocution
0.033 5 15 1
Fire N/A
Shock
0.033 5 0.5 1
Burn N/A
Electrocution N/A
Fire N/A
Shock N/A
Burn Motor control incorporates overload
protection
0.033 5 0.5 1
Electrocution N/A
Fire N/A
Shock N/A
Burn
0.033 5 0.5 1
Electrocution
0.033 5 15 1
Fire N/A
Shock
0.033 5 0.5 1
Burn
0.033 5 0.5 1
Electrocution
0.033 5 15 1
Fire N/A
Shock
0.033 5 0.5 1
Burn N/A
Electrocution N/A
Fire N/A
Shock N/A
Other N/A
Burn N/A
Dehydration N/A
Discomfort N/A
Frostbite N/A
Injuries from radiated heat N/A
Scald N/A
Burn N/A
Dehydration N/A
Discomfort N/A
Frostbite N/A
Scald N/A
Burn N/A
Dehydration N/A
Discomfort N/A
Frostbite N/A
Scald N/A
Burn N/A
Dehydration N/A
Discomfort N/A
Frostbite N/A
Scald N/A
Other N/A
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
acoustic signals.
N/A
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Discomfort
Only source of significant noise is
gearmotor
1 5 0.5 4
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Discomfort Only low noise from out-of-balance
cable drum
0.033 5 0.5 4
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Discomfort Potential for leaks from pneumatic
components
0.033 5 0.5 4
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Discomfort Gearmotor and bearings are lightly
stressed, so unlikely to wear
0.033 5 0.5 4
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
N/A
Other N/A
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
Discomfort N/A
Discomfort N/A
Discomfort N/A
Discomfort No human contact with machine
while it is running
0.033 0 0.5 0
Discomfort No human contact with machine
while it is running
0.033 0 0.5 0
Discomfort Gearmotor and bearings are lightly
stressed, so unlikely to wear
0.033 5 0.5 4
Other N/A
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
Burn N/A
Burn N/A
Burn N/A
Other N/A
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
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation 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
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation 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
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation 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
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation 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
Cancer N/A
Corrosion N/A
Explosion N/A
Fire N/A
Infection N/A
Mutation N/A
Poisoning N/A
Sensitisation 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
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 N/A
Discomfort N/A
Fatigue N/A
Musculoskeletal disorder N/A
Stress N/A
a consequence of human error N/A
Discomfort Illuminated on/off switch and
pneumatic pressure gauge well
placed for easy visibility
0.033 5 0.5 1
Fatigue N/A
Stress N/A
Discomfort Illuminated on/off switch and
pneumatic regulator well placed for
easy accessibility
0.033 5 0.5 1
Fatigue N/A
Stress N/A
Discomfort Full cable reel max 5kg so minimal
effort required
0.033 5 0.5 1
Fatigue Full cable reel max 5kg so minimal
effort required
0.033 5 0.5 1
Stress N/A
Discomfort N/A
Fatigue N/A
Stress N/A
Discomfort N/A
Fatigue N/A
Stress N/A
Discomfort N/A
Fatigue N/A
Stress N/A
Discomfort N/A
Fatigue N/A
Stress N/A
Discomfort N/A
Fatigue N/A
Stress N/A
Discomfort N/A
Fatigue N/A
Stress N/A
Other N/A
Burn N/A
Slight disease N/A
Slipping or falling N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Burn N/A
Slight disease N/A
Suffocation N/A
the machine N/A
Other N/A
heat stroke N/A
N/A
N/A
N/A
N/A
N/A
N/A
LO FE DPH NP
Discomfort, musculoskeletal disorder
Check if safe for one person to lift
machine unassisted
0.033 0.5 2 1
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A Supplied fully assembled
Potential injury during drilling of
holes
Use good working practices 0.033 0.5 6 1
Potential for electric shock and injury
from compressed air Standard mains lead supplied with
machine; use good working practices
when connecting to air supply
0.033 0.5 15 1
Initial assessment
N/A
Impact from dancing arm Supply machine with regulator turned
down to minimum; include warning in
instructions
0.033 0.5 2 1
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Cable reel could work loose Ensure clamp nut is tight 1 5 0.5 1
N/A
N/A Max cable drum weight is 5kg
N/A
N/A
N/A
N/A
N/A
Machine could restart unexpectedly
if dancing arm moved from bottom
position
Ensure machine is switched off
before removing cable drum
2 5 2 1
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
All components specified to last the
lifetime of the machine
N/A
N/A
N/A
N/A
N/A
N/A
Hazards from electrical and
pneumatic energy
Ensure machine is isolated from
energy supplies before dismantling
2 0.5 15 1
N/A
N/A
N/A
Machine could restart unexpectedly Ensure machine is isolated from
energy supplies before attempting to
clear jam
2 1 2 1
pneumatic energy
2 0.5 15 1
pneumatic energy
2 0.5 15 1
N/A
N/A
N/A
N/A
pneumatic energy
2 0.5 15 1
N/A
N/A
Discomfort, musculoskeletal disorder
Check if safe for one person to lift
machine unassisted
0.033 0.5 2 1
N/A
N/A
N/A
N/A
N/A
LO FE DPH NP
See above
See above
See above
N/A
Crushing or impact from cable drum
if it works loose See above
See above
N/A
See above
See above
See above
See above
See above
N/A
N/A
N/A
See above
Crushing or impact from cable drum
if it works loose See above
Machine could fail to stop if control
circuit is faulty
0.033 5 2 1
N/A
N/A
Machine could start unexpectedly if
control circuit is faulty
N/A
N/A
N/A
See above
Initial assessment
See above
See above
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
2.5 Negligible None 0 Negligible
Action required
80 High Fit interlocked
guarding
0.033 5 2 1 0.33 Negligible
guarding
0.033 5 2 1 0.33 Negligible
2.475 Negligible Include warning in
instructions
0.033 5 15 1 2.475 Negligible
guarding
0.033 5 2 1 0.33 Negligible
20 Low, significant Fit interlocked
guarding
0.033 5 2 1 0.33 Negligible
0.0825 Negligible Ensure instructions
refer to secure
anchoring
0 Negligible
4.95 Negligible Use proven
components and best-
practice design
0 Negligible
1 Negligible Use best-practice
design (material choice
for pulleys); include
warning in instructions
0 Negligible
0.0825 Negligible Use best-practice
design
0 Negligible
design
0 Negligible
design
0 Negligible
design
0 Negligible
design
0 Negligible
design
0 Negligible
design
0 Negligible
design
0 Negligible
design
0 Negligible
design
0 Negligible
10 Low, significant Use sound meter to
check noise levels. If
excessive, enclosure
gearmotor
0.033 5 0.5 4 0.33 Negligible
0 Negligible None 0 Negligible
0.033 Negligible Ergonomic
assessment
0 Negligible
0.099 Negligible Use good working
practices
0 Negligible
0.2475 Negligible Use good working
practices
0 Negligible
Re-assessment after taking action Initial assessment
Action required
0.033 Negligible Supply machine with
regulator turned down
to minimum; include
warning in instructions
0 Negligible
20 Low, significant Install interlocked
guarding
0.033 5 2 1 0.33 Negligible
15 Low, significant Warnings on machine
and in instructions;
competence of
technician
0.033 0.5 15 1 0.2475 Negligible
4 Negligible Warnings on machine
and in instructions
0 Negligible
competence of
technician
0.033 0.5 15 1 0.2475 Negligible
0.033 0.5 15 1 0.2475 Negligible
competence of
technician
0.033 0.5 15 1 0.2475 Negligible
0.033 Negligible Ergonomic
assessment
0 Negligible
0.33 Negligible Design control circuits
to appropriate
standards
0 Negligible
Initial assessment
Action required
Action required
None
None
None
None
None
None
Action required
None
None
None
None
None
Action required

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