If you are designing a new production line or are considering expanding an existing one, you should begin by developing a machine risk assessment. This is a process that will require you to identify hazards and controls, redundancy, and future scenarios. Listed below are the steps for a complete Machine risk assessment. You can get the help of outside experts if you need it. To get started, download a template and follow it step by step.

Identifying hazards

When a manufacturing company changes the design of a machine or introduces a new product, it should perform a hazard identification assessment. Once the hazard has been identified, the company may add a hazard sign or implement a training program. If the hazard is particularly dangerous, the company may decide to add additional controls. In such cases, the hazard identification assessment may determine that additional safeguards should be installed.

To identify the hazards, a company must identify the tasks performed by workers. Workers are usually better informed than managers, so they are often consulted in the process. Instruction manuals for certain machinery and products may contain information about their inherent risks. In addition, records of ill-health and accidents may reveal patterns in which certain hazards are associated with certain types of incidents. A machine risk assessment is vital for preventing ill-health and accidents.

Identifying controls

Before identifying controls for machine risk assessment, it is essential to collect information about the machine. Identify its limits, lifecycle requirements, energy sources, design drawings and sketches, and system descriptions. You should also note any previous incident history, health risks, or details about system layouts. Once you have this information, you can proceed to the next step: creating a list of potential hazards. These risks may include:

When identifying controls for a machine, it is important to keep in mind that different personnel may use different techniques. While implementing controls, keep in mind that they will have varying degrees of impact on the workplace. Regardless, the purpose of a risk assessment is to protect workers from injury. It is therefore crucial to identify these behaviors, as they can set up serious hazards. If you fail to identify these risks, the machine may continue to cause harm.

Identifying redundancy

Machines can experience a failure, but redundancy can make a huge difference in minimizing the consequences. When redundant assets are used together, they reduce risk and increase operational flexibility. If one asset fails, the other can take its place and continue to meet demand. The following are some important benefits of redundancy for your machines. Read on to learn more about why redundancy is an important part of machine risk assessments.

Data redundancy refers to information stored in multiple places. This is common in many businesses, especially those that use multiple systems to store information. Many businesses store their information in silos, but a central database makes reconciliation difficult. To overcome this problem, you must track data redundancy. Once you have identified the locations where your data is redundant, you can develop a plan to mitigate the problems that can result from inconsistency.

Identifying future scenarios

One of the most important steps in assessing machine safety is to identify possible future scenarios. This is a crucial component of any risk assessment, as it can help ensure that a hazard is avoided. Identifying future scenarios is particularly important when new machinery has not been commissioned yet, or if it has not been used for a long time. Fortunately, there are ways to incorporate future scenarios into your analysis.

For instance, consider an independent themed scenario, where the team chooses a specific criterion to examine and evaluate a range of possible future scenarios. This strategy allows teams to think outside of the box and identify potential problems. For example, the team might think about the response to a sudden change in the price of gasoline. In contrast, a team might choose a scenario that isolates individual categories of change and then asks participants to create possible future scenarios within those categories.

Documenting results

Performing task-based machine risk assessments is critical for industrial plant safety. An industry-specific standard is available for performing and documenting machine risk assessments. The American National Standards Institute (ANSI) has published guidelines for performing and documenting this important process. Most people don’t realize the significant cost savings associated with risk assessments. For example, one study conducted by Liberty Mutual concluded that risk assessments saved their company three cents for every dollar invested in safety. OSHA’s office of regulatory affairs is even more optimistic, estimating a savings of four to six cents per dollar invested in safety.

The results of a risk assessment help determine the limits of a machine and associated tasks. Once the limits are established, hazards associated with tasks are assessed and weighted according to their severity, likelihood of occurrence, and ability to be avoided. Ultimately, the result of this process is an accurate document of a machine’s risks. The final risk assessment document serves as a tool for defense in the event of a lawsuit or accident.