Risk Assessment Calculator V4

RISK ASSESSMENT CALCULATOR

Ref. Std.:- EN ISO 14121-1

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How to use this Risk Assessment Calculator

TUV INDIA P LTD.

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 14121-1:2007 (Safety of machinery. Risk assessment. Principles). The Risk Assessment Calculator is based on Annex A of EN ISO 14121-1,

Seven worksheets are provided: 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 and a list of hazardous events. See BS EN ISO 14121-1 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.

LO (Likelihood of Occurrence) FE (Frequency of Exposure)0.033 Almost impossible Only in extreme circumstances 0.5 Annually1 Highly unlikely Though conceivable 1 Monthly1.5 Unlikely But could occur 1.5 Weekly2 Possible But unusual 2.5 Daily5 Even chance Could happen 4 Hourly8 Probable Not surprising 5 Constantly10 Likely To be expected15 Certain No doubt

DPH (Degree of Possible Harm) NP (Number of Persons at risk)0.1 Scratch or bruise 1 1-2 persons0.5 Laceration or mild ill-effect 2 3-7 persons2 Break of minor bone or minor illness (temporary) 4 8-15 persons4 Break of major bone or major illness (temporary) 8 16-50 persons6 Loss of one limb, eye, hearing (permanent) 12 50+ persons10 Loss of two limbs or eyes (permanent)15 Fatality

HRN Risk0-5 Negligible5-50 Low, significant50-500 HighOver 500 UnacceptableHazard Rating No. (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:

Machines requiring action

Action required:

Assessment reference: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 carried out by:Assessment date:Assessment checked by:Assessment approved by:

Origin

Mechanical hazards

Angular parts

Type or group of hazard

Kinetic energy (causing acceleration or deceleration)

Approach of a moving element to a fixed part

Cutting parts

Elastic elements

Falling objects

Stored energy (gravity)

Height from the ground

High pressure

Machinery mobility

Moving elements

Rotating elements

Surface finish (rough or slippery)

Sharp edges

Stability

Vacuum

OtherElectrical hazards Arc

Electromagnetic phenomena

Live parts

Overload

Insufficient distance from live parts under high voltage

Short-circuit

Thermal radiation

OtherThermal hazards Explosion

Flame

Radiation from heat sources

OtherNoise hazards Cavitation phenomena

Parts becoming live under fault conditions

Objects or materials with a high or low temperature

Exhaust system

High-speed gas leak

Moving parts

Manufacturing process (eg stamping, pressing, grinding)

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

OtherRadiation hazards Ionising radiation source

Low-frequency electromagnetic radiation

Optical radiation (infrared, visible and ultraviolet), including laser

OtherMaterial/substance hazards Aerosol

Combustible

Dust

Explosive


Radio frequency electromagnetic radiation

Biological and microbiological (viral or bacterial) agent

Fibre

Flammable

Fluid

Fume

Gas

Mist

Oxidiser

OtherErgonomic hazards Access

Effort

Local lighting

Design or location of indicators and visual display units

Design, location or identification of control devices

Flicker, dazzling, shadow, stroboscopic effect

Mental overload or underload

Posture

Repetitive activity

Visibility

OtherDust and fog

Electromagnetic disturbance

Lighting

Hazards associated with the environment in which the machine is used

Moisture

Pollution

Snow

Temperature

Water

Wind

Lack of oxygen

OtherCombined hazards

Hazardous situations (tasks)

Tasks

Transport LiftingLoadingPackingTransportationUnloadingUnpackingOther tasks

Assembly of the machineFixing, anchoring

Fencing

TestingRunning the machine without loadTrials with load or maximum loadDemonstrationOther tasks

eg repetitive activity + effort + high environmental temperature

Phase of machine lifecycle

Assembly, installation and commissioning

Preparations for installation (eg foundations, vibration isolators)

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

Feeding, filling, loading of ancillary fluids (eg lubricants, adhesives)

Setting, teaching, programming and/or process changeover

Mounting or changing tools, tool-setting

Adjustment and setting of protective devices and other components

Clamping/fastening the workpiece

Program verificationFunctional test, trialsVerification of the final productOther tasks

Operation Clamping/fastening the workpiece

Manual loading/unloadingOperating manual controlDriving the machine

Control/inspectionSupervisionVerification of the final productOther tasks

Cleaning and maintenance AdjustmentsCleaning, disinfection

HousekeepingIsolation and energy dissipationLubricationReplacement of tools

Removal and disposal of spent fluids

Restoring fluid levels

Other tasksFault-finding/trouble-shooting Adjustments

Fault-finding

Adjustment and setting or verification of functional parameters of the machine (eg speed, pressure, force, travel limits)

Feeding, filling, loading or raw material


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

Dismantling/removal of parts, components, devices of the machine

Replacement of worn or damaged parts

Verification of parts, components, devices of the machine


Isolation and energy dissipation

Recovering from jamRepairing

Rescue of trapped personsResetting

Other tasksDecommissioning and dismantling Disconnection and energy dissipation

DismantlingRemoval and disposal of spent fluids

LiftingLoadingPackingTransportationUnloadingOther tasks

Hazardous events

Origin related to Hazardous event

Contact with rough edges

Moving parts of the machine Contact with moving partsContact with rotating open endsFalling or ejection of objects

Loss of stability

Displacement of moving elementsProjection of high-pressure fluidsUncontrolled movements

Electrical equipment Direct contactDisruptive dischargeElectric arcFireIndirect contact

Recovering from control and protective devices failure

Replacement of parts, components, devices of the machine


Shape and/or superficial finishing of accessible parts of the machine Contact with sharp edges and

corners, protruding parts

Kinetic energy and/or potential energy (gravity) of the machine, parts of the machine, tools and materials used, processed or handled

Stability of the machine and/or parts of the machine

Mechanical stiffness/strength of parts of the machine, tools, etc

Deflection or break-up during operation

Pneumatic and hydraulic equipment

Short-circuitControl system

Failure to stop moving parts

Unintended/unexpected start-up

Harsh environmental conditionsExcessive effort

Painful and/or tiring posturesRepetitive handling at high frequency

Other Other events

Dropping or ejection of a moving parts of the machine or of a workpiece clamped by the machine

Machine action resulting from inhibition (defeating or failure) of protective devices

Uncontrolled movements (including speed changes)

Other hazardous events due to failure(s) or poor design of the control system

Materials and substances or physical factors (temperature, noise, vibration, radiation and environment)

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

Emission of a level of noise that can 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

Workstation and/or work process design Human errors/misbehaviour

(unintentional and/or deliberately induced y the design)

Loss of direct visibility of the working area

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 Initial assessment

LO FE DPH NPBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglement

Potential consequences

Friction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpact

InjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearing

Slipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturing

SuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationOtherBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particles

ShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockOtherBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldOtherDiscomfortLoss of awarenessLoss of balance

Permanent hearing lossStressTinnitusTiredness

DiscomfortLoss of awarenessLoss of balancePermanent hearing lossStressTinnitusTiredness




Other (eg mechanical or electrical) as a consequence of an interference with speech communication or with acoustic signals.








Other






DiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderOtherBurnDamage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcBurnDamage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcBurn

Damage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcBurnDamage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcOtherBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capability

ExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutation

PoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationOtherDiscomfortFatigueMusculoskeletal disorderStress

DiscomfortFatigueMusculoskeletal disorderStress




Discomfort

Other (eg mechanical, electrical) as a consequence of human error





FatigueMusculoskeletal disorderStress





OtherBurnSlight diseaseSlipping or fallingSuffocation

BurnSlight diseaseSlipping or fallingSuffocation







Any other as a consequence of the effect caused by the sources of the hazards on the machine or parts of the machine
















Other

Consequences CommentsInitial assessment

LO FE DPH NP


eg dehydration, loss of awareness, heat stroke

Consequences Comments Initial assessment

LO FE DPH NP

Initial assessmentAction required

Re-assessment after taking action

HRN Risk level LO FE DPH NP HRN Risk level0 Negligible 0 Negligible

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible





0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible



0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

0 Negligible 0 Negligible









0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible






0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible





0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible











0 Negligible 0 Negligible0 Negligible 0 Negligible




HRN Risk level LO FE DPH NP HRN Risk level



0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible































HRN Risk level LO FE DPH NP HRN Risk level0 Negligible 0 Negligible0 Negligible 0 Negligible



















Action required

Action required

Action required

Assessment reference: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 carried out by:Assessment date:Assessment checked by:Assessment approved by:

Origin

Mechanical hazards

Angular parts




Cutting parts

Elastic elements

Falling objects



High pressure

Machinery mobility

Moving elements

Rotating elements


Sharp edges

Stability

Vacuum



Live parts

Overload


Short-circuit

Thermal radiation


Flame





Exhaust system

High-speed gas leak

Moving parts


Scraping surfaces



Worn parts

Other

Vibration hazards Cavitation phenomena


Mobile equipment

Scraping surfaces


Vibrating equipment

Worn parts





Combustible

Dust

Explosive




Fibre

Flammable

Fluid

Fume

Gas

Mist

Oxidiser


Effort

Local lighting





Posture

Repetitive activity

Visibility

OtherDust and fog


Lighting


Moisture

Pollution

Snow

Temperature

Water

Wind

Lack of oxygen



Tasks

Transport LiftingLoadingPackingTransportationUnloadingUnpackingOther tasks


Fencing

















Control/inspectionSupervisionVerification of the final productOther tasks




Restoring fluid levels


Fault-finding












Isolation and energy dissipation

Recovering from jamRepairing


Other tasksDecommissioning and dismantling Disconnection and energy dissipation

DismantlingRemoval and disposal of spent fluids

LiftingLoadingPackingTransportationUnloadingOther tasks

Hazardous events




Loss of stability


Electrical equipment Direct contactDisruptive dischargeElectric arcFireIndirect contact











Short-circuitControl system





Other Other events













(unintentional and/or deliberately induced y the design)


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 NPBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglement


Friction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpact

InjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearing

Slipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturing

SuffocationBeing run overBeing thrownCrushingCutting or severingDrawing-in or trappingEntanglementFriction or abrasionImpactInjectionShearingSlipping, tripping or fallingStabbing or puncturingSuffocationOtherBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particles

ShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockBurnChemical effectsEffects on medical implantsElectrocutionFalling or being thrownFireProjection of molten particlesShockOtherBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldBurnDehydrationDiscomfortFrostbiteInjuries from radiated heatScaldOtherDiscomfortLoss of awarenessLoss of balance

Permanent hearing lossStressTinnitusTiredness













Other






DiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderDiscomfortLow-back diseaseNeurological disorderOsteo-articular disorderTrauma of the spineVascular disorderOtherBurnDamage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcBurnDamage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcBurn

Damage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcBurnDamage to eyes and skinEffects on reproductive capabilityGenetic mutationHeadache, insomnia, etcOtherBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capability

ExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutation

PoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationBreathing difficulties, suffocationCancerCorrosionEffects on reproductive capabilityExplosionFireInfectionMutationPoisoningSensitisationOtherDiscomfortFatigueMusculoskeletal disorderStress





Discomfort






FatigueMusculoskeletal disorderStress





OtherBurnSlight diseaseSlipping or fallingSuffocation
























Other


LO FE DPH NP




LO FE DPH NP




0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible




















0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible


























HRN Risk level LO FE DPH NP HRN Risk level





















































Action required

Action required

Action required

Assessment reference: 0101Type of machine: Cable re-reelerMachine location: Building 01, cable sectionMachine description:

Machine manufacturer: CableMagicMachine model: CM01Machine serial number: 0000123Modifications from 'as-supplied': NoneEnergy sources: Electricity, compressed air

Energy source ratings: 240V AC; 6bar pressure

Safety measures:

Assessment carried out by: A. PersonAssessment date: 09 November 2007Assessment checked by: A. N. Other PersonAssessment approved by: A. Third Person

Origin

Mechanical hazards

Angular parts

Machine re-reels cable following marking or measuring operations on other machines.

Emergency stop button connected to safety relay - isolates power and operates dump valve.



Cutting parts

Elastic elements

Falling objects




High pressure

Machinery mobility

Moving elements

Rotating elements


Sharp edges

Stability

Vacuum



Live parts

Overload



Short-circuit

Thermal radiation


Flame




Exhaust system

High-speed gas leak

Moving parts


Scraping surfaces



Worn parts

OtherVibration hazards Cavitation phenomena


Mobile equipment

Scraping surfaces


Vibrating equipment

Worn parts



Combustible

Dust





Explosive

Fibre

Flammable

Fluid

Fume

Gas

Mist

Oxidiser




Effort

Local lighting


Posture

Repetitive activity

Visibility

OtherDust and fog




Lighting

Moisture

Pollution

Snow

Temperature

Water

Wind

Lack of oxygen



Tasks

Transport Lifting

LoadingPackingTransportationUnloadingUnpackingOther tasks






Fencing






Control/inspectionSupervision















Verification of the final productOther tasks



Removal and disposal of spent fluidsRestoring fluid levels


Fault-findingIsolation and energy dissipation

Recovering from jam

Repairing


Other tasksDecommissioning and dismantling

Disconnection and energy dissipationDismantling


LiftingLoadingPackingTransportation








UnloadingOther tasks

Hazardous events




Loss of stability


Electrical equipment Direct contactDisruptive dischargeElectric arcFireIndirect contactShort-circuit

Control system



















Other Other events






(unintentional and/or deliberately induced by the design)


Number of operatives: 1Number of shifts per week: 5Usage (hours per month): 35Operating 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:

Maintenance training record:

Access by untrained visitors: None


LO FE DPH NPBeing run over N/ABeing thrown N/ACrushing 1 5 0.5 1

Cutting or severing N/ADrawing-in or trapping 8 5 2 1

Entanglement 1.5 5 0.5 1

Friction or abrasion 8 5 0.5 1

Impact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/A

Yes, held in maintenance dept (last serviced 3 months ago).

Maintenance manager trained during installation of machine.


Rotating cable reel (approx 5kg, card or plastic flanges, no sharp edges) could become detached.

Nip point where cable is wound onto reel

Exposed end of shaft on which cable reel is mounted

Rotating cable reel (card or plastic flanges, no sharp edges, up to 100 rpm, max 250mm dia).

Impact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping 8 5 2 1

Entanglement N/AFriction or abrasion N/AImpact 8 5 2 1

Injection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/A

Pneumatic-actuated (10mm cylinder) 'dancing arm' could trap hand or finger

Pneumatic-actuated (10mm cylinder) 'dancing arm' could strike hand or finger

Entanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing 0.033 5 15 1

Suffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/A

Escaping compressed air could enter the blood stream

Friction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing 1 5 0.5 1

Cutting or severing 0.033 5 0.5 1

Drawing-in or trapping 8 5 2 1

Entanglement 1.5 5 0.5 1

Friction or abrasion 8 5 0.5 1

Impact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion 0.033 5 0.1 1

Impact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/A

Rotating cable reel (approx 5kg, card or plastic flanges, no sharp edges) could become detached.


Nip point where cable is wound onto reel

Exposed end of shaft on which cable reel is mounted


Potential for inadequately finished cast, machined and other surfaces

Suffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing 0.5 5 0.1 1

Drawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact 0.033 5 0.5 1

Injection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/ABeing run over N/ABeing thrown N/ACrushing N/ACutting or severing N/ADrawing-in or trapping N/AEntanglement N/AFriction or abrasion N/AImpact N/AInjection N/AShearing N/ASlipping, tripping or falling N/AStabbing or puncturing N/ASuffocation N/AOther N/ABurn N/AChemical effects N/AEffects on medical implants N/AElectrocution N/AFalling or being thrown N/AFire N/AProjection of molten particles N/AShock N/ABurn N/AChemical effects N/A

Potential for inadequately finished cast, machined and other edges

Snagged cable could cause re-reeler to tip over

Effects on medical implants Potential for stray EMI 0.033 5 15 2

Electrocution N/AFalling or being thrown N/AFire N/AProjection of molten particles N/AShock N/ABurn 0.033 5 0.5 1

Chemical effects N/AEffects on medical implants N/AElectrocution 0.033 5 15 1

Falling or being thrown N/AFire N/AProjection of molten particles N/AShock 0.033 5 0.5 1

Burn N/AChemical effects N/AEffects on medical implants N/AElectrocution N/AFalling or being thrown N/AFire N/AProjection of molten particles N/AShock N/ABurn 0.033 5 0.5 1

Chemical effects N/AEffects on medical implants N/AElectrocution N/AFalling or being thrown N/AFire N/AProjection of molten particles N/AShock N/ABurn 0.033 5 0.5 1



All electrical components contained within earthed metal machine casing



Motor control incorporates overload protection




Burn 0.033 5 0.5 1



Burn N/AChemical effects N/AEffects on medical implants N/AElectrocution N/AFalling or being thrown N/AFire N/AProjection of molten particles N/AShock N/AOther N/ABurn N/ADehydration N/ADiscomfort N/AFrostbite N/AInjuries from radiated heat N/AScald N/ABurn N/ADehydration N/ADiscomfort N/AFrostbite N/AInjuries from radiated heat N/AScald N/ABurn N/ADehydration N/ADiscomfort N/AFrostbite N/AInjuries from radiated heat N/AScald N/ABurn N/ADehydration N/ADiscomfort N/AFrostbite N/AInjuries from radiated heat N/AScald N/AOther N/ADiscomfort N/ALoss of awareness N/ALoss of balance N/APermanent hearing loss N/AStress N/ATinnitus N/A




Tiredness N/AN/A

Discomfort N/ALoss of awareness N/ALoss of balance N/APermanent hearing loss N/AStress N/ATinnitus N/ATiredness N/A

N/A


N/A


N/A

Discomfort 1 5 0.5 4

Loss of awareness N/ALoss of balance N/APermanent hearing loss N/AStress N/ATinnitus N/ATiredness N/A





Only source of significant noise is gearmotor

N/ADiscomfort N/ALoss of awareness N/ALoss of balance N/APermanent hearing loss N/AStress N/ATinnitus N/ATiredness N/A

N/ADiscomfort 0.033 5 0.5 4








Only low noise from out-of-balance cable drum


Potential for leaks from pneumatic components


Gearmotor and bearings are lightly stressed, so unlikely to wear

N/AOther N/ADiscomfort N/ALow-back disease N/ANeurological disorder N/AOsteo-articular disorder N/ATrauma of the spine N/AVascular disorder N/ADiscomfort N/ALow-back disease N/ANeurological disorder N/AOsteo-articular disorder N/ATrauma of the spine N/AVascular disorder N/ADiscomfort N/ALow-back disease N/ANeurological disorder N/AOsteo-articular disorder N/ATrauma of the spine N/AVascular disorder N/ADiscomfort N/ALow-back disease N/ANeurological disorder N/AOsteo-articular disorder N/ATrauma of the spine N/AVascular disorder N/ADiscomfort 0.033 0 0.5 0

Low-back disease N/ANeurological disorder N/AOsteo-articular disorder N/ATrauma of the spine N/AVascular disorder N/ADiscomfort 0.033 0 0.5 0

Low-back disease N/ANeurological disorder N/AOsteo-articular disorder N/ATrauma of the spine N/AVascular disorder N/ADiscomfort 0.033 5 0.5 4

Low-back disease N/ANeurological disorder N/AOsteo-articular disorder N/ATrauma of the spine N/AVascular disorder N/AOther N/ABurn N/ADamage to eyes and skin N/A


No human contact with machine while it is running

No human contact with machine while it is running

Gearmotor and bearings are lightly stressed, so unlikely to wear

Effects on reproductive capability N/AGenetic mutation N/AHeadache, insomnia, etc N/ABurn N/ADamage to eyes and skin N/AEffects on reproductive capability N/AGenetic mutation N/AHeadache, insomnia, etc N/ABurn N/ADamage to eyes and skin N/AEffects on reproductive capability N/AGenetic mutation N/AHeadache, insomnia, etc N/ABurn N/ADamage to eyes and skin N/AEffects on reproductive capability N/AGenetic mutation N/AHeadache, insomnia, etc N/AOther N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/A

Fire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/A

Sensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/ABreathing difficulties, suffocation N/ACancer N/ACorrosion N/AEffects on reproductive capability N/AExplosion N/AFire N/AInfection N/AMutation N/APoisoning N/ASensitisation N/AOther N/ADiscomfort N/AFatigue N/AMusculoskeletal disorder N/AStress N/A


Fatigue N/AMusculoskeletal disorder N/AStress N/A


Fatigue N/AMusculoskeletal disorder N/AStress N/A

N/A


Illuminated on/off switch and pneumatic pressure gauge well placed for easy visibility


Illuminated on/off switch and pneumatic regulator well placed for easy accessibility


Discomfort 0.033 5 0.5 1

Fatigue 0.033 5 0.5 1

Musculoskeletal disorder N/AStress N/A

N/ADiscomfort N/AFatigue N/AMusculoskeletal disorder N/AStress N/A






N/AOther N/ABurn N/ASlight disease N/ASlipping or falling N/ASuffocation N/A

N/ABurn N/A

Full cable reel max 5kg so minimal effort required

Full cable reel max 5kg so minimal effort required









Slight disease N/ASlipping or falling N/ASuffocation N/A

N/ABurn N/ASlight disease N/ASlipping or falling N/ASuffocation N/A














N/AOther N/A

N/AN/AN/AN/AN/AN/AN/A


LO FE DPH NP

Discomfort, musculoskeletal disorder0.033 0.5 2 1

N/AN/AN/AN/AN/AN/A

N/AN/A Supplied fully assembledPotential injury during drilling of holes Use good working practices 0.033 0.5 6 1





Check if safe for one person to lift machine unassisted

0.033 0.5 15 1

N/A

Impact from dancing arm 0.033 0.5 2 1

N/A

N/AN/AN/AN/AN/AN/A

N/A

N/A

N/AN/A

N/AN/AN/AN/AN/ACable reel could work loose Ensure clamp nut is tight 1 5 0.5 1

N/AN/A Max cable drum weight is 5kgN/AN/A

N/A

N/A

N/A2 5 2 1

N/AN/A

Potential for electric shock and injury from compressed air Standard mains lead supplied with

machine; use good working practices when connecting to air supply

Supply machine with regulator turned down to minimum; include warning in instructions

Machine could restart unexpectedly if dancing arm moved from bottom position

Ensure machine is switched off before removing cable drum

N/AN/AN/AN/A

N/AN/AN/AN/AN/A

N/A

N/AN/A

N/AN/AN/A

2 0.5 15 1

N/AN/A

N/AMachine could restart unexpectedly 2 1 2 1

2 0.5 15 1

2 0.5 15 1

N/AN/AN/A

N/A2 0.5 15 1

N/A

N/A

Discomfort, musculoskeletal disorder0.033 0.5 2 1

N/AN/AN/A

All components specified to last the lifetime of the machine

Hazards from electrical and pneumatic energy

Ensure machine is isolated from energy supplies before dismantling

Ensure machine is isolated from energy supplies before attempting to clear jam







Check if safe for one person to lift machine unassisted

N/AN/A


LO FE DPH NPSee above

See aboveSee above

N/A

See above

See above

N/ASee aboveSee aboveSee aboveSee aboveSee above

N/AN/AN/A

See above

See above0.033 5 2 1

N/A

N/A

N/A

N/A

N/A

Crushing or impact from cable drum if it works loose

Crushing or impact from cable drum if it works looseMachine could fail to stop if control circuit is faulty

Machine could start unexpectedly if control circuit is faulty

See above

See above

See above

N/AN/AN/A

N/A

N/AN/A

N/AN/A




2.5 Negligible None 0 Negligible

0 Negligible 0 Negligible80 High Fit interlocked guarding 0.033 5 2 1 0.33 Negligible


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

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

80 High Fit interlocked guarding 0.033 5 2 1 0.33 Negligible



0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

2.475 Negligible 0.033 5 15 1 2.475 Negligible


Include warning in instructions

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible





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

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible





0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

0.0825 Negligible 0 Negligible

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible

Ensure instructions refer to secure anchoring
















Use proven components and best-practice design

Use best-practice design












0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible








10 Low, significant 0.033 5 0.5 4 0.33 Negligible


Use sound meter to check noise levels. If excessive, enclosure gearmotor










0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible None 0 Negligible

0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible None 0 Negligible






0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible






























HRN Risk level LO FE DPH NP HRN Risk level0.033 Negligible Ergonomic assessment 0 Negligible



0 Negligible None 0 Negligible0.099 Negligible 0 NegligibleUse good working

practices











0 Negligible 0 Negligible2.5 Negligible None 0 Negligible


0 Negligible None 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible



20 Low, significant 0.033 5 2 1 0.33 Negligible


Use good working practices

Supply machine with regulator turned down to minimum; include warning in instructions

Install interlocked guarding


0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible None 0 Negligible




15 Low, significant 0.033 0.5 15 1 0.2475 Negligible






0 Negligible 0 Negligible15 Low, significant 0.033 0.5 15 1 0.2475 Negligible


0.033 Negligible Ergonomic assessment 0 Negligible


Warnings on machine and in instructions; competence of technician

Warnings on machine and in instructions











0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible0 Negligible 0 Negligible








Design control circuits to appropriate standards









Action required

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Action required

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Action required

Documents

Risk Assessment Calculator V4