1. Why should I have a formal assessment done?
To help ensure that your machines are guarded correctly
(safe), ensure safeguards are compliant with applicable
standards, make sure the machine remains productive after
the guarding is installed and to save money by doing it right
the first time. OSHA sites a 6-to-1 benefit to cost ratio and
Liberty Mutual states a 3-to-1 benefit to cost ratio when
investing in safeguarding and safeguarding programs. The
key to realizing this benefit to cost ratio is making sure the
machines are safeguarded correctly. Information gathered
by Omron STI indicates that 93% of the machines on the
factory floor are not guarded in accordance with relevant
regulations and standards. The proper and best way to
safeguard a machine correctly and ensure the existing
safeguards are adequate is by conducting and documenting
a machine safeguarding assessment to validate the selected
safeguarding system.
2. What is the value and advantage of a
documented machine safeguarding assessment/
risk reduction plan?
A documented machine safeguarding assessment provides
a clear plan to reduce risk and bring non-compliant
machines into compliance. The report contains a high level
overview as well as machine-specific risk
reduction recommendations based on
the identified risk level of the equipment
as used in your production facility. The
format of the report is designed to help
communicate the current status of your
machine safeguarding program to all
levels within your organization.
A documented assessment also helps
establish priorities for safeguarding based
on identified risk levels. This assists in
targeting funds where the most benefit will
be realized while also planning for future
upgrades. The documented assessment
can be used for years to come to ensure
machines remain in compliance by
comparing the machine’s existing guarding
system with the detailed guarding
recommendations and drawings in the
assessment, allowing any deviations to be
easily identified and addressed.
The assessment / risk reduction report can serve to show
OSHA, your insurance company and corporate headquarters
what the action plan is to achieve compliance.
3. What is the assessment process?
The assessment process is a two part process (Risk Level
Identification and Risk Reduction).
Risk Level Identification – The process of interacting
with your operators and maintenance personnel to
understand the intended use of the machine, the tasks and
hazards, and the level of risk associated with their operation
of the equipment.
Risk Reduction – The application of protective
measures in a manner that both reduces the risk to a
tolerable level and achieves compliance with applicable
regulations and standards. The goal is to have a machine
that is both safe and productive.
4. What information should be derived from the
assessment report?
As mentioned, the assessment is a two part process and
you will want to make sure that the report addresses both
parts. It is very important to ensure that the assessment
company provides you with a written report that contains
usable information and includes a
specific and detailed strategy on how to
guard the machine correctly to achieve
maximum safety and productivity. At
a minimum, the report should contain
information such as:
1. Applicable safety standards or
regulations reviewed and considered
during the assessment.
2. Overview of the assessment process
and method used to determine the
risk level for each machine.
3. Explanation of the risk reduction
requirements that will be applied
based on risk level.
4. Machine identification (manufacturer,
type, model number, serial number,
asset number, location, etc).
5. Types of hazards associated with the
machine.
6. Description of the hazards
associated with the machine.
7. Risk factors and model used to
determine the risk level for the
machine.
8. Risk reduction (safeguarding
measures) performance
requirements to acheive
compliance, based on the risk
level for this machine.
9. Safety-related control system (safety circuits)
performance requirements to achieve compliance,
based on the risk level for this machine.
10. Residual risk level for this machine if the recommended
safeguarding measures are installed in accordance
with all applicable regulations and standards (estimated
risk level after guarding using the assessor’s
detailed recommendations).
11. Risk reduction (safeguarding) recommendations with
detailed written information covering the type and and a description of how they will be applied to
reduce the risk to a tolerable level of risk.
12. A drawing showing the guarding strategy concept and
approximate location of the guards and safety devices
on the machine.
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