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MACHINE BUILDING, FRAMEWORKS & SAFETY FEATURE
IDENTIFYING HAZARDS: HOW TO ASSESS
RISKS IN MACHINERY
This article, part of EUCHNER’s series on machinery safety for industrial equipment designers, highlights the vital role of risk assessments
EVALUATING AND CONTROLLING MACHINERY RISKS
Following hazard identification, the next step is risk evaluation – assessing both the likelihood and severity of potential harm. Effective control measures follow a hierarchy: eliminating hazards entirely, substituting hazardous processes with safer alternatives, and implementing engineering controls such as barriers and interlocks. Administrative controls, including safety procedures, training, and signage, promote awareness and compliance. Finally, PPE serves as the last line of defence.
THE ONGOING ROLE OF RISK ASSESSMENTS Risk assessments are not one-time activities. Regular reviews are essential, particularly when new machinery is introduced, processes change, incidents occur, or workers identify hazards. Both designers and operators share responsibility for maintaining safety through ongoing risk management.
D
espite strong awareness of occupational health and safety issues such as slips, trips, falls, and working at height,
machinery safety often suffers from a knowledge gap. Addressing this gap requires a solid understanding of risk assessment principles, particularly those outlined in BS EN ISO 12100:2010, which establishes essential practices for hazard identification and risk reduction.
THE IMPORTANCE OF RISK ASSESSMENT IN MACHINERY SAFETY Machinery safety is critical for protecting operators, maintenance personnel, and the workplace environment. Effective risk assessments help identify, evaluate, and control hazards, ensuring both legal compliance and operational efficiency. A proper risk assessment process, as described in BS EN ISO 12100:2010, is fundamental to safe machine design and operation.
BRIDGING THE GAP IN MACHINERY SAFETY AWARENESS While industries generally excel in managing common workplace hazards like slips, trips, and falls, machinery safety often receives less attention. This discrepancy stems from a lack of understanding of machinery-specific risks and the importance of structured risk assessments. Comprehensive risk assessments, aligned with BS EN ISO 12100:2010, are essential to closing this gap.
UNDERSTANDING MACHINERY HAZARDS AND THEIR RISKS Effective risk assessments begin with identifying hazards. Mechanical hazards, such as moving parts, sharp edges, and crushing points, can cause entanglement, cuts, or amputations, often due to inadequate guarding or maintenance. Electrical hazards from exposed conductors,
faulty wiring, or poor insulation can lead to shocks or electrocution, which effective isolation and grounding procedures can mitigate. Thermal hazards from hot surfaces or high-temperature machinery, such as boilers or furnaces, can cause burns or fires without proper shielding and ventilation. Prolonged exposure to high noise levels from equipment like compressors or cutting tools can lead to hearing loss without appropriate noise-dampening measures or personal protective equipment (PPE). Vibration hazards from prolonged use of
vibrating tools may cause musculoskeletal disorders, such as Hand-Arm Vibration Syndrome (HAVS), which ergonomic tools and protective gear can help reduce. Poorly designed workstations can cause ergonomic hazards, contributing to repetitive strain injuries and chronic pain, which adjustable machinery and ergonomic training can prevent. Additionally, chemical hazards from
exposure to toxic substances, often encountered during spraying, welding, or processing, may cause respiratory issues or skin irritation, making proper ventilation and protective equipment essential.
THE IMPORTANCE OF MACHINERY SAFETY COMPETENCE Achieving a high level of machinery safety requires not only risk assessments and technical safeguards but also competence among those involved in design, operation, and maintenance. Mark Staples of EUCHNER (UK) advocates
training as a key enabler and path towards competence. He emphasises that knowledge and experience empower individuals to identify and mitigate risks effectively. The EUCHNER Academy has supported many professionals on their journey to competence by providing targeted training and resources, ensuring they are well-equipped to promote and maintain a safe working environment.
FINAL THOUGHTS Machinery safety is essential for preventing workplace injuries and fatalities. Bridging the existing knowledge gap requires consistent application of structured risk assessments and adherence to standards like BS EN ISO 12100:2010. Promoting competence through training, as advocated by EUCHNER (UK) and supported by the EUCHNER Academy, is key to enabling individuals to implement safety practices effectively. By committing to regular risk assessments, competence development, and comprehensive safety practices, both designers and machine operators can significantly reduce risks and create a safer working environment.
EUCHNER (UK) T: 0114 2560123
www.euchner.co.uk
FEBRUARY 2025 DESIGN SOLUTIONS 19
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