Introduction to Risk Assessment

Safety of Machinery Series

AIHS Webinar

S. Ivkovic, A. Hallinan

Pilz Australia

20th October 2020

What is Risk Assessment?

A risk assessment involves considering what could happen if someone is exposed to a hazard

(consequence) and the likelihood of it happening.

A risk assessment can help you determine:

How severe a risk is;

Whether existing control measures are effective;

What action you should take to control the risk; and

How urgently the action needs to be taken.

Why conduct a Risk Assessment?

WHS Regulation #34 - Duty to identify hazards

A duty holder, in managing risks to health and safety, must identify reasonably foreseeable hazards that

could give rise to risks to health and safety.

WHS Regulation #35 – Managing risks to health and safety

A duty holder, in managing risks to health and safety, must:

a) eliminate risks to health and safety so far as is reasonably practicable; and

b) if it is not reasonably practicable to eliminate risks to health and safety—minimise those risks so far

as is reasonably practicable.

Victorian and Western Australian legislation also mentions these points in the relevant Acts and

Regulations.

Information on Risk Assessment

AS/NZS 4024.1-2014 Safety of machinery series contains 25 Parts that are European (EN) and

Internationally-based (ISO) safety and design Standards with some modifications to meet Australia's

tough safety practices and regulations.

The series provides designers, manufacturers, suppliers, employers and users of machinery with

guidelines to help reduce the risks of working with, or near, machinery.

This webinar will cover information you can find in the following standards:

AS/NZS 4024 Part 1201: General principles for design—Risk assessment and risk reduction

AS/NZS 4024 Part 1303: Risk assessment—Practical guidance and examples of methods

Risk Assessment Process as Defined in AS/NZS 4024.1201

Limits of the Machinery

Intended to provide a clear description of the mechanical and

physical properties, functional capabilities of the machinery, its

intended use and reasonably foreseeable misuse, and the type of

environment in which it is likely to be used and maintained.

Typical information gathered includes:

Make/Model/Serial No. details

Intended use of machine

Energy sources

Description of control system

Modes of operation

Raw materials

Required skills of operators

Housekeeping and Maintenance

Hazard Identification

Inspect each item of plant in your workplace and observe how it is used.

Talk to your workers and their health and safety representatives to find out

what their experience is with the plant they operate, inspect or maintain.

All hazards associated with the machine should be considered even if

there are suitable risk controls in place.

You should consider whether:

The plant could cause injury due to entanglement, falling, crushing,

trapping, cutting, puncturing, shearing, abrasion or tearing

The plant could create hazardous conditions due to harmful emissions,

fluids or gas under pressure, electricity, noise, radiation, friction,

vibration, fire, explosion, moisture, dust, ice, hot or cold parts, and

The plant could cause injury due to poor ergonomic design - for

example, if operator controls are difficult to reach or require high force to

operate

Risk Estimation

There are many methods used to estimate Risk Levels. It does not

matter what method you use so long as it gives consideration to

the severity of injury and likelihood of occurrence and gives you the

ability to prioritise the risks that you have.

Remember risk estimation is subjective, not a precise science.

Some of the more commonly used risk estimation methods are:

Risk Matrix

Risk Graph

Hazard Rating Number

Risk Score Calculator

You can find details on some of these methods and examples in

AS/NZS 4024.1303

Risk Estimation

Hazard Rating Number (HRN)

Numerical values are assigned to the following factors in order to evaluate the risk related with a

hazard:

The Likelihood of Occurrence (LO)

The Frequency of Exposure (FE)

The Degree of Possible Harm (DPH)

The Number of Persons at risk (NP)

The Hazard Rating Number has then been calculated from the following formula:

Hazard Rating Number (HRN)

Likelihood of Occurrence (LO)

0.033 Almost impossible

1 Highly Unlikely

1.5 Unlikely

2 Possible

5 Even Chance

8 Probable

10 Likely

15 Certain

Degree of Possible Harm (DPH)

0.1 Scratch / Bruise

0.5 Laceration / cut / mild ill health effect

1 Fracture: minor bone – fingers/ toes

2 Fracture- major bone – hand/ arm/ leg

4 Loss of 1 or 2 fingers/ toes

8 Leg / hand amputation, partial loss of hearing or eye

10 Amputation of 2 legs/hands, total loss of hearing/sight

xx in both ears/eyes

12 Critical or permanent illness

15 Fatality

Number of Persons at risk (NP)

1 1- 2 persons

2 3-7 persons

4 8-15 persons

8 16-50 persons

12 More than 50 persons

Frequency of Exposure (FE)

0.5 Annually

1 Monthly

1.5 Weekly

2.5 Daily

4 Hourly

5 Constantly

Risk Evaluation

When evaluating risk you need to consider whether you have

achieved your risk reduction objectives.

The hazard has been eliminated or the risk reduced as far as

reasonably practicable

The safeguarding selected is of a type which, by experience, is

safe for the intended use

The type of safeguarding selected is appropriate for the

application in terms of

probability of defeat or circumvention;

severity of harm; and

hindrance to the execution of the required task

The operating procedures for the use of the machinery are

consistent with the ability of personnel who use the machinery

Acceptable Risk?

If an acceptable level is not achieved then Risk Reduction

Measures must be implemented.

Example – Semi Automatic Rotary Table Wrapper Machine

Example – Semi Automatic Rotary Table Wrapper Machine

This machine facilitates the semi-automatic wrapping of goods placed on a timber pallet. The loaded

pallet is placed on the rotary turn-table

A film spool dispenses plastic film which is routed through rollers on an automatic film shears which

will cut the film at the end of the wrapping process

The film spool will be hoisted while the turntable is in motion to wrap in a vertical direction

The rotation of turn-table will alternate between clockwise and counter clockwise for each wrapping

cycle

Wrapping cycle speeds, number of wrapping layers and rotational torque are fully adjustable via a

HMI screen on the control panel

The machine is stopped, started and reset via push buttons on the control panel, or via a wireless

controller

The operator loaded pallets 3 times an hour

The film spool is replaced daily

Maintenance is performed monthly

Example – Semi Automatic Rotary Table Wrapper Machine

Machine in Operation

Semi Automatic Rotary Table Wrapper Machine

Machine Component Parts

Machine Component Parts

Machine Component Parts

Machine Component Parts

Machine Loading/Unloading

Risk Assessment Process

Step 1 – Identify Limits of the Machine

Step 1 – Identify Limits of the Machine

Risk

Evaluation

Risk

Reduction

Required

Ref No. Lifecycle Task LO FE DPH NP HRNNegligible -

UnacceptableYes/No

0

Operation

Maintenance

Set-up

Changing

SpoolY/N

1

Operation

Maintenance

Set-up

Electrical

MaintenanceY/N

Operation

Maintenance

Set-up

Y/N

Accident Scenario Risk Estimation

Hazard Identification

Machine Inspector Date

Hazard Zone Identified Hazard

Working Zone

Operator Station

Possible crushing hazard between the film

spool holder and metal floor plate

Exposed electrical parts present a possible

electrocution hazard

Step 2 – Identify Hazards

Step 3 – Estimate the Risk

Step 4 – Evaluate the Risk

Step 5 – Acceptable Risk

Step 6 – Risk Reduction

Hierarchy of Control Measures needs to be employed when

considering means of reducing risk:

1. Elimination

2. Substitution

3. Isolation

4. Engineering Controls

5. Administrative Controls

6. Personal Protective Equipment

Machine Specific Standards

AS/NZS 4024 Part 3 standards give risk reduction solutions for

specific machines types

The wrapping machine is included in:

AS 4024.3406:2018 Safety of packaging machines – Pallet

wrapping machines

Machinery Safety Lifecycle

Example – Semi Automatic Rotary Table Wrapper Machine

More information

Pilz training courses https://www.pilz.com/en-AU/trainings

MachineSAFE Introduction – 1 day course covers legislation, standards, guarding and introduction to

Risk Assessment

MachineSAFE Comprehensive – 2 day course covers introduction plus more in depth in RA, LoTo,

electrical safety and safety control systems

Risk Assessment Workshop – 1 day course focusing on Risk Assessment with practical examples

Certified Machinery Safety Expert CMSE® - 4 day course certified by TÜV Nord

Pilz can perform a Risk Assessment as one of the many services we offer

Pilz Safety Compendium is aimed at all those in mechanical and plant

engineering who deal with the issue of functional safety and its associated aspects.

External Reference Documents

AIHS BoK Chapter 28: Mechanical Plant

AS/NZS 4024.1:2019

WHS Model Code of Practice: Managing risks of plant in the workplace

Victorian Compliance code: Plant

WA Code of practice – Safeguarding of machinery and plant

Webinar – Updates to AS/NZS 4024.2019

Name: What is new in AS/NZS 4024

Duration: 1.5 hours webinar, 0.5 hours Q&A

Date: November 12, 2020

Time: 10:00 AM to 12:00 PM (AEST)

Cost: $237.00

To register please send an email to: office@pilz.com.au or visit www.pilz.com.au

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www.pilz.com.au

Pilz Australia1/12-14 Miles StreetMulgrave, 3170, Victoria Tel: 1300 723 334Tel: +61 3 9560 0621services@pilz.com.au

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