Annually, over 395 million workplace accidents are reported globally. A concerning statistic, as published by the International Labour Organization (ILO) (https://www.ilo.org/) in 2023. Performing a thorough Risk Assessment as mandated by the EN ISO 12100 Standard is a critical first step in ensuring worker safety.
The Normative context
The EN ISO 12100:2010 Standard, “Safety of machinery – General principles of design – Risk assessment and risk reduction” – a type A Standard – is a solid methodological guide for identifying hazards, assessing risks and implementing the appropriate mitigation measures for each type of industrial machinery. Its in-depth analysis is essential for all manufacturers, installers and employers who want to protect the safety of workers by complying with current legal requirements.
The Primary Regulatory Reference for Designers and Manufacturers
Together with the harmonized standards on Control Systems (EN ISO 13849) and on the Functional Safety of Machinery (EU EN IEC 62061 – Safety Integrity Levels (SIL)), the EN ISO 12100 Standard acts as the main reference for designers and manufacturers in order to comply with the Essential Safety Requirements as per Machinery Directive/New Machinery Regulation and to be able to legally place their products on the market.
The Legal Requirement for Employers
For employers who set up industrial machinery, conducting a meticulous Risk Assessment is not just a best practice but a legal requirement, as specified by International Directives and National Workplace Safety Laws.
What Does Risk Assessment Entail?
Risk Assessment involves evaluating potential hazards throughout the entire lifecycle of a machine to pinpoint the necessary preventative actions against injuries and damages. It's a critical step required by each Competent Authority for both new installations and when upgrading existing equipment.
The Importance of Risk Assessment
Executing a precise Risk Assessment not only enhances worker safety but also protects the organization from potential penalties while ensuring smooth industrial operations by preventing machine downtime resulting from accidents.
Risk Assessment Step-by-Step
Outlined by EN ISO 12100, the Risk Assessment process involves a structured approach. While specific methods may vary, the essential principles are consistent and include five key steps:
1. Hazard identification
Inspect the workplace to spot potential hazards. Assess the operational limitations of machines, consider all mechanical, electrical, or thermal hazards, perhaps also referring to manufacturer’s or supplier's guidelines, and examine incident or near-miss records.
2. Risk Assessment
Analyze how, where, when, and the duration for which workers are exposed to potential hazards. Assign a risk level to each identified hazard using a risk matrix and evaluate any remaining risks.
3. Decision on Control Measures
4. Documentation of results
Documenting the process and outcomes in a Periodic Risk Assessment Register is crucial for maintaining an ongoing record of identified hazards, risks, and safety measures.
5. Review and Update of Assessments
Monitor the implementation of recommended controls and conduct any necessary corrective actions before commissioning. Any changes that might alter hazard conditions require a new Risk Assessment by the employer.
Integrated Prevention Solutions
Following the analysis of risks, it becomes feasible to implement a comprehensive system of Safety Measures by integrating protective measures that are both collective (like Standards-Compliant Perimeter Guards, Stops and Interlocking Devices, Safety Signs), and personal (Personal Protective Equipment -PPE and Staff training), as well as Organizational Measures such as regular maintenance and inspections. A systemic way of acting aimed at maximizing Safety and minimizing Residual Risks.
