Hazard Identification
Identify mechanical, electrical, motion, stored-energy, access and automation-related hazards.
Machinery Safety Engineering
Safety risk assessment for machines and automated systems.
Practical machinery-safety reviews covering hazards, access, guarding, interlocks, emergency stops, light curtains, scanners, safe zones, safety-control interfaces and risk-reduction recommendations.
SAFETY RISK ASSESSMENT
IDENTIFY
ASSESS
REDUCE
ASSESS
REDUCE
Assessment Scope
Risk assessment connected to how the machine actually operates.
The review considers normal production, cleaning, setup, fault recovery, maintenance, manual intervention and foreseeable abnormal conditions—not only the machine in automatic mode.
Risk Evaluation
Document hazardous tasks, exposure, potential consequences and required risk-reduction actions.
Safeguarding Review
Review fixed/movable guards, interlocks, light curtains, scanners, safe distances and access points.
E-Stop & Safe States
Review emergency-stop coverage, stop behaviour, reset philosophy and safe restart conditions.
Safety Controls Review
Review safety-PLC interfaces, safety I/O, safe-drive signals, zone status and standard/safety PLC handshakes.
Risk Register & Actions
Provide structured findings, recommended controls, priorities and documentation for remediation planning.
Define Machine & Tasks
Confirm machine boundaries, users, operating modes, interventions and maintenance activities.
- Automatic operation
- Manual / setup modes
- Cleaning
- Fault recovery
- Maintenance access
Identify Hazards
Review hazardous motion, crushing/shearing, entanglement, ejection, stored energy and access to danger zones.
- Conveyors and robots
- Actuators and lifts
- Pinch / crush points
- Unexpected startup
- Energy isolation interfaces
Review Existing Controls
Assess the risk-reduction measures already implemented and how they interact with the control system.
- Guards / interlocks
- Light curtains
- Safety scanners
- E-stops
- Safety PLC / drive safety
Recommend Risk Reduction
Define practical engineering actions to reduce residual risk and improve maintainability.
- Guarding changes
- Access-control changes
- Safety-function improvements
- Diagnostic improvements
- Procedural controls where appropriate
Documentation & Follow-Up
Document findings and support implementation planning or subsequent verification activities.
- Risk register
- Action list
- Controls recommendations
- Open risks
- Retest / validation planning
Standards-Aware Approach
Machinery safety principles appropriate to the project.
Reviews can consider relevant machinery-safety risk-management principles and standards, including the AS 4024 series and ISO 12100 where applicable to the agreed scope.
Important: A risk assessment or controls review does not automatically constitute statutory certification, independent functional-safety validation, plant registration or regulatory sign-off. Where formal verification, validation, certification or specialist sign-off is required, that scope must be explicitly defined and completed by appropriately competent/qualified parties.
System Graphic
Machinery safety assessment
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