Risk Assessment Calculator

www.machinesafety.co.
uk
guards@procterbedwas.co.uk
1
6
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 machin
General principles for design. Risk assessment and risk reduction). If required, contact Procter Machine Guarding for advic
specialists who can assist with complex risk assessments. The Risk Assessment Calculator is based on Annex B of BS EN
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) Regulatio
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
the machine, as the Machinery Directive requires that information about the residual risks must be included in the instructio
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 assess
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
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 colu
will automatically show 'negligible' for these risks. For each applicable hazard, use the Look-Up Table to choose appropriat
values for the Likelihood of Occurrence (LO), Frequency of Exposure (FE), Degree of Possible Harm (DPH) and Number o
Persons at risk (NP). In addition to the list of hazards, there is also a list of hazardous situations (tasks) and a list of hazard
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
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 meas
a risk is 'High' if there are potentially dangerous hazards that require control measures to be implemented urgently; and a r
'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 th
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
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:
Machines requiring action

Worksheet reference: Machine reference:
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:
Type or group of
Origin
hazard
Mechanical hazards Acceleration/deceleration
Kinetic energy
Angular parts
Approach of a moving element to a
fixed part
Cutting parts
Elastic elements
Falling objects
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
Insufficient distance from live parts
under high voltage
Overload
Parts becoming live under fault

conditions
Short-circuit
Thermal radiation
Other
Thermal hazards Explosion
Flame
Objects or materials with a high or

low temperature
low temperature
Radiation from heat sources
Other
Noise hazards Cavitation phenomena
Exhaust system
High-speed gas leak
Manufacturing process (eg stamping,

pressing, grinding)
Moving parts
Scraping surfaces
Unbalanced rotating parts
Whistling pneumatics
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
Low-frequency electromagnetic
radiation
Optical radiation (infrared, visible

and ultraviolet), including laser
Radio frequency electromagnetic

radiation
Other
Material/substance hazards Aerosol
Biological and microbiological (viral

or bacterial) agent
Combustible
Dust
Explosive
Fibre
Flammable
Fluid
Fume
Gas
Mist
Oxidiser
Other
Ergonomic hazards Access
Design or location of indicators and

visual display units
Design, location or identification of

control devices
Effort
Flicker, dazzling, shadow,

stroboscopic effect
Local lighting
Mental overload or underload
Posture
Repetitive activity
Visibility
Other
Hazards associated with the Dust and fog
environment in which the machine
is used
Electromagnetic disturbance
Lighting
Moisture
Pollution
Snow
Temperature
Water
Wind
Lack of oxygen
Other
Combined hazards eg repetitive activity + effort + high
environmental temperature
Hazardous situations (tasks)
Phase of machine
Tasks
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
Program verification
Functional test, trials
Verification of the final product
Other tasks
Operation Clamping/fastening the workpiece
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
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
Dismantling
Lifting
Loading
Packing
Transportation
Unloading
Other tasks
Hazardous events
Origin related to Hazardous event
Shape and/or superficial finishing Contact with rough surfaces

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
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:
Potential Initial assessment

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

0 Negligible 0 Negligible

Action required


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:
Type or group of
Origin
hazard
Kinetic energy
Angular parts
fixed part
Cutting parts
Elastic elements
Falling objects
Gravity
Stored energy
High pressure
Machinery mobility
Moving elements
Rotating elements
Sharp edges
Instability
Vacuum
Other
Live parts
under high voltage
Overload

conditions
Short-circuit
Thermal radiation
Other
Flame

low temperature
low temperature
Other
Exhaust system
High-speed gas leak

pressing, grinding)
Moving parts
Scraping surfaces
Worn parts
Other
Mobile equipment
Scraping surfaces
Vibrating equipment
Worn parts
Other
radiation


radiation
Other

or bacterial) agent
Combustible
Dust
Explosive
Fibre
Flammable
Fluid
Fume
Gas
Mist
Oxidiser
Other


control devices
Effort

stroboscopic effect
Local lighting
Posture
Repetitive activity
Visibility
Other
is used
Lighting
Moisture
Pollution
Snow
Temperature
Water
Wind
Lack of oxygen
Other
Phase of machine
Tasks
lifecycle
Transport Lifting
Loading
Packing
Transportation
Unloading
Unpacking
Other tasks
Fixing, anchoring
components
Fencing
Testing
Demonstration
Other tasks
travel limits)
Other tasks
Driving the machine
limits)
Control/inspection
Supervision
Other tasks
Housekeeping
Lubrication
parts
Resetting
Other tasks
Fault-finding
Recovering from jam
Repairing
Resetting
Other tasks
Dismantling
Lifting
Loading
Packing
Transportation
Unloading
Other tasks
Hazardous events

handled
Electric arc
Fire
Indirect contact
Short-circuit
protective devices
speed changes)
control system
be hazardous
signals
can be hazardous
be hazardous
area
Other Other events
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:

Comments
consequences
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
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
Initial assessment
LO FE DPH NP
Initial assessment
LO FE DPH NP
Action required


Action required


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
Type or group of
Origin
hazard
Kinetic energy
Angular parts

fixed part
Cutting parts
Elastic elements
Falling objects
Gravity
Stored energy
High pressure
Machinery mobility
Moving elements
Rotating elements

Sharp edges
Instability
Vacuum
Other
Live parts

under high voltage
Overload

conditions
Short-circuit
Thermal radiation
Other
Flame

low temperature
Other
Exhaust system
High-speed gas leak

pressing, grinding)
Moving parts
Scraping surfaces
Worn parts
Other
Mobile equipment
Scraping surfaces
Vibrating equipment
Worn parts
Other
radiation


radiation
Other
or bacterial) agent
Combustible
Dust
Explosive
Fibre
Flammable
Fluid
Fume
Gas
Mist
Oxidiser
Other

control devices
Effort

stroboscopic effect
Local lighting
Posture
Repetitive activity
Visibility
Other
is used
Lighting
Moisture
Pollution
Snow
Temperature
Water
Wind
Lack of oxygen
Other
Phase of machine
Tasks
lifecycle
Transport Lifting
Loading
Packing
Transportation
Unloading
Unpacking
Other tasks
Fixing, anchoring


components
Fencing
Testing
Demonstration
Other 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
Electric arc
Fire
Indirect contact
Short-circuit

protective devices
speed changes)

control system
be hazardous
signals
can be hazardous
be hazardous
design
Workstation and/or work process
area
Other Other events
Number of operatives: 1
Number of shifts per week: 5
Usage (hours per month): 35
Operating manuals: Yes, as supplied
Standard operating procedures: Yes, adjacent to machine.

Operatives' training record: Yes, held in HR file.
Warning signs: One, relating to pinch hazard.
Raw materials: Electrical cable up to 3mm diameter.
Maintenance manual: Yes, held in maintenance dept (last
serviced 3 months ago).
Maintenance training record: Maintenance manager trained during
installation of machine.
Access by untrained visitors: None

Comments
consequences
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 1 5 0.5 1
or plastic flanges, no sharp edges)
could become detached.
Cutting or severing
Entanglement
Impact
Injection
Shearing
Suffocation
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 'dancing arm' could trap hand or 8 5 2 1
finger
Entanglement N/A
Impact Pneumatic-actuated (10mm cylinder) 8 5 2 1
'dancing arm' could strike hand or
finger
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 0.033 5 15 1
the blood stream
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 1 5 0.5 1
or plastic flanges, no sharp edges)
could become detached.
Cutting or severing Rotating cable reel (card or plastic 0.033 5 0.5 1
flanges, no sharp edges, up to 100
rpm, max 250mm dia).
Drawing-in or trapping Nip point where cable is wound onto 8 5 2 1
reel
Entanglement Exposed end of shaft on which cable 1.5 5 0.5 1
reel is mounted
Friction or abrasion Rotating cable reel (card or plastic 8 5 0.5 1
flanges, no sharp edges, up to 100
rpm, max 250mm dia).
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 0.033 5 0.1 1
cast, machined and other surfaces
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 0.5 5 0.1 1
cast, machined and other edges
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 0.033 5 0.5 1
to tip over
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 2 5 0.1 1
Static charge could build up where

cable passes over pulleys
Burn All electrical components contained 0.033 5 0.5 1
within earthed metal machine casing
Electrocution All electrical components contained 0.033 5 15 1
Fire N/A
Shock All electrical components contained 0.033 5 0.5 1
Burn N/A
Electrocution N/A
Fire N/A
Shock N/A
Burn Motor control incorporates overload 0.033 5 0.5 1
protection
Electrocution N/A
Fire N/A
Shock N/A
Fire N/A
Fire N/A
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
Other (eg mechanical or electrical) N/A
acoustic signals.
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
acoustic signals.
Discomfort 1 5 0.5 4
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
Discomfort N/A
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
Discomfort Only low noise from out-of-balance 0.033 5 0.5 4
cable drum
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
Discomfort Potential for leaks from pneumatic 0.033 5 0.5 4
components
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness N/A
Discomfort Gearmotor and bearings are lightly 0.033 5 0.5 4
stressed, so unlikely to wear
Loss of balance N/A
Stress N/A
Tinnitus N/A
Tiredness 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 0.033 0 0.5 0
while it is running
Discomfort No human contact with machine 0.033 0 0.5 0
while it is running
Discomfort Gearmotor and bearings are lightly 0.033 5 0.5 4
stressed, so unlikely to wear
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 0.033 5 0.5 1
pneumatic pressure gauge well
placed for easy visibility
Fatigue N/A
Stress N/A
Discomfort Illuminated on/off switch and 0.033 5 0.5 1
pneumatic regulator well placed for
easy accessibility
Fatigue N/A
Stress N/A
Discomfort Full cable reel max 5kg so minimal 0.033 5 0.5 1
effort required
Fatigue Full cable reel max 5kg so minimal 0.033 5 0.5 1
effort required
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
Initial assessment
LO FE DPH NP
Check if safe for one person to lift 0.033 0.5 2 1
Discomfort, musculoskeletal disorder machine unassisted
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A Supplied fully assembled
Potential injury during drilling of Use good working practices 0.033 0.5 6 1
holes
Potential for electric shock and injury Standard mains lead supplied with 0.033 0.5 15 1
from compressed air machine; use good working practices
when connecting to air supply
N/A
Impact from dancing arm Supply machine with regulator 0.033 0.5 2 1
turned down to minimum; include
warning in instructions
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 Ensure machine is switched off 2 5 2 1
if dancing arm moved from bottom before removing cable drum
position
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
N/A lifetime of the machine
N/A
N/A
N/A
N/A
N/A
N/A
Hazards from electrical and Ensure machine is isolated from 2 0.5 15 1
pneumatic energy energy supplies before dismantling
N/A
N/A
N/A
Machine could restart unexpectedly Ensure machine is isolated from 2 1 2 1
energy supplies before attempting to
clear jam

N/A
N/A
N/A
N/A
N/A
N/A
Check if safe for one person to lift 0.033 0.5 2 1
Discomfort, musculoskeletal disorder machine unassisted
N/A
N/A
N/A
N/A
N/A
Initial assessment
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 0.033 5 2 1
circuit is faulty
N/A
N/A
Machine could start unexpectedly if
control circuit is faulty
N/A
N/A
N/A
See above
See above
See above
N/A
N/A
N/A
N/A
N/A
N/A
N/A
N/A
Action required

2.5 Negligible None 0 Negligible
80 High Fit interlocked 0.033 5 2 1 0.33 Negligible
guarding
guarding
2.475 Negligible Include warning in 0.033 5 15 1 2.475 Negligible
instructions

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

guarding
0.0825 Negligible Ensure instructions 0 Negligible
refer to secure
anchoring
4.95 Negligible Use proven 0 Negligible
components and best-
practice design
1 Negligible Use best-practice 0 Negligible
design (material choice
for pulleys); include
0.0825 Negligible Use best-practice 0 Negligible
design
design
design
design
design
design
design
design
design
design
10 Low, significant Use sound meter to 0.033 5 0.5 4 0.33 Negligible

check noise levels. If
excessive, enclosure
gearmotor
0 Negligible None 0 Negligible

Action required

0.033 Negligible Ergonomic 0 Negligible
assessment
0.099 Negligible Use good working 0 Negligible
practices
0.2475 Negligible Use good working 0 Negligible
practices
0.033 Negligible Supply machine with 0 Negligible

regulator turned down
to minimum; include
20 Low, significant Install interlocked 0.033 5 2 1 0.33 Negligible

guarding
15 Low, significant Warnings on machine 0.033 0.5 15 1 0.2475 Negligible
and in instructions;
competence of
technician
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 Negligible Ergonomic 0 Negligible
assessment
Action required

0.33 Negligible Design control circuits 0 Negligible

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

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

Source: Pilz Guide to Machinery Safety, 6th Edition

Machines requiring action

Height from the ground

Surface finish (rough or slippery)

Parts becoming live under fault

Objects or materials with a high or

Radiation from heat sources

High-speed gas leak

Manufacturing process (eg stamping,

Unbalanced rotating parts

Unbalanced rotating parts

Optical radiation (infrared, visible

Radio frequency electromagnetic

Biological and microbiological (viral

Design or location of indicators and

Design, location or identification of

Flicker, dazzling, shadow,

Mental overload or underload

Hazardous situations (tasks)

Origin related to Hazardous event

Shape and/or superficial finishing Contact with rough surfaces

Potential Initial assessment

HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

HRN Risk level LO FE DPH NP HRN Risk level

Height from the ground

Surface finish (rough or slippery)

Parts becoming live under fault

Objects or materials with a high or

Radiation from heat sources

High-speed gas leak

Manufacturing process (eg stamping,

Unbalanced rotating parts

Unbalanced rotating parts

Optical radiation (infrared, visible

Radio frequency electromagnetic

Biological and microbiological (viral

Design or location of indicators and

Design, location or identification of

Flicker, dazzling, shadow,

Mental overload or underload

Hazardous situations (tasks)

Origin related to Hazardous event

Shape and/or superficial finishing Contact with rough surfaces

Potential Initial assessment

HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

HRN Risk level LO FE DPH NP HRN Risk level

Initial assessment Re-assessment after taking action

HRN Risk level LO FE DPH NP HRN Risk level

Energy source ratings: 240V AC; 6bar pressure

Safety measures: Emergency stop button connected to

Approach of a moving element to a

Height from the ground

Surface finish (rough or slippery)

Insufficient distance from live parts

Parts becoming live under fault

Objects or materials with a high or

Radiation from heat sources