Fundamentals of Risk Analysis for Machinery

One of the most important part of technical files prepared under the 2006/42/AT Machine Safety Regulation is Risk Analysis. Risk analysis should be performed in the design stage for every situation applicable for the machine. In this way, it is possible to identify the dangers for the manufacturer machine and the risks associated with it, taking the necessary measures. In this article we will inform you about the basics of risk analysis to be done for machines.

For risk assessment for machines EN 12100 The standard is the most applicable source. EN 12100 While the standard defines methods to be applied for safe design depending on the purpose of use of the machine, general dangers in the machine and a comprehensive guide for the operation of risk assessment to dispose of them.

EN ISO 12100 Risk Assessment in guidance consists of a number of logical stages. This schematic display is given below.

EN 12100 Let’s review the stages for Risk Assessment to be made according to the standard below.

1. Determination of Functions / Limits of the Machine

Risk assessment starts with determining the limits of the machines by taking into account all stages of the machine life. This detection means that the machine or a number of machines in an integrated structure should be determined according to the limits of the machines related to people, the environment and the products. These can be as follows;

• Different machine operation modes for users and different intervention procedures,
• The use of machines (e.g., industrial, non-industrial and housing) by people set according to the hand or limiting physical properties (division or hearing barrier, size, durability, etc.) used in gender, age, most used,
• Training levels and experience of users,
• Other people are exposed to dangers related to machines,
• The points regarding the limitations of the place to attend the delegation (such as the open area, the operator-machine interface, the machine-power supply interface),
• Life limit of some of the components of the machine and/or machine,
• Maintenance, cleaning, service ranges, environmental conditions
• Features of the material/materials to be processed,

•  Determination of dangers

After determining the limits of the machine, it is necessary to determine the hazards that may be predicted during the realization of all stages within the lifetime cycle of the machine. These stages can be sorted as follows with general lines;

• Shipping, assembly and installation
• Getting To Business
• Tuning
• Normal operation
• Maintenance, Cleaning
• Dismantling, dismantling, destruction

The machine manufacturer should take into account the following hazards for the whole of the above stages.

• Mechanical hazards
• Electrical hazards
• Pneumatic and hydraulic hazards
• Ergonomic hazards
• Heat-borne hazards
• Risks caused by noise
• Dangers caused by vibration
• Risks caused by radiation
• The dangers caused by material and permanent materials
• Dangers caused by slip, jewelry or fall
• Risks related to the environment where the machine is used

• Risk Forecast

A risk estimate should be carried out for each dangerous situation in mind after the dangers are determined.

Detected risks can be sampled as follows;

 

• Risk Assessment

There are various selections, e.g. tables, risk charts, numeric methods, etc for the estimated risk of risks. INSPECCO as the methods we use for risk assessment in machinery Phone Number (HRN) method. The degree of risk with HRN varies depending on the following parameters.

• Possible to come to the square (OL)
• Maruz stay frequency (MKS)
• Degree of damage (MZD)
• Number of people affected by risk (KS)

The risk ratings corresponding to the numerical expressions revealed as a result of risk assessment are explained below.

• Reduce Risk

After risk assessment, various steps should be followed for risk reduction if required according to the risk value. These steps are as follows according to the priority order;

1. Physical Caps: Fixed enclosures, civiçli enclosures, self-locking enclosures, etc.
2. Protection Automation Equipment: Light barriers, space scanners, safety mats, double control systems, bass run controls, safety PLCs etc.
3. Personal Protective Equipment: Use of glasses, headphone, baret, gloves etc.
4. Instructions and Prohibitions: Providing instructions for the machine with the instruction manual, specifying prohibited applications.

Physical Caps	Protective Housings
Personal Protective Equipment	Instructions and Alerts

The priority in the above-mentioned protection methods is to minimize the possibility of contact with risky zones by making physical or automation changes on the machine. Alerts made with instructions in places detected in high risk are not enough risk reduction methods to use personal protective equipment or training given to the staff.

As a result of the measures taken, the risk level should not be reached to the safe level, the current risk should be evaluated again and additional measures must be reached to the safe level. It is not always possible to eliminate risk completely. It is essential to reduce the risk of the technique and technology to the extent the hand, and to make alerts for the remaining risks.

You can contact us to make the risk assessment of your machinery and facilities.