Risk assessment is fundamental to machine safeguarding. The goal of a safety system is to reduce risk to an acceptable level with risk being defined as a task & hazard pair. If the risk assessment and the risk reduction are implemented properly, the safety system will be integral with the machine and allow employees safe access to perform their required tasks in a safe, yet, unencumbered way. A safety system that is burdensome is likely to be bypassed or circumvented in the name of expediency and productivity. Also, the risk reduction measure should not create new hazards.

The risk assessment process includes the steps of analyzing the inherent risks of the machine, tasks that cause people to be exposed to those inherent risks, and ultimately includes the application of risk reduction methods as well as documenting the results. The whole process should also be considered as an iterative process in which all task & hazard pairs are assessed for severity, frequency, and possibility of avoidance. The risk assessment result would be a category and/or performance level recommendation that risk reduction measures must meet.

If the residual risk is not deemed to be acceptable (tolerable), then the process should be repeated to determine what additional reduction measures need to be applied. However, risk assessment also allows that not all risks can be eliminated or reduced within reasonable economic limits. Whether or not the residual risk is determined to be acceptable is ultimately the responsibility of the end user.

The best approach to performing a risk assessment is as a team, allowing the input of different opinions as to what tasks need to be performed and what hazards exist. Operators, as well as maintenance staff, should be included along with engineers, management, safety staff, and other employees that can offer useful opinions and information. You should also consider bringing “outsiders” to the team for these people can bring specific safety expertise to the process that, otherwise, may be lacking on your team. ANSI B11.0: 2020 now includes a list of responsibilities for the supplier and user of machinery and recommends points of potential collaboration. The machine manufacturer is now responsible for sharing the assessment with the user (for new or rebuilt machines). The user, in the past, was solely responsible for machine safety. If the assessment program is properly structured initially, a risk assessment will result in the identification of hazards that were overlooked previously or allowed to exist because they were not covered by any standard. The assessment should be expanded beyond human injury to cover damage to the machine and other company assets as well as damage to the environment. This will result in a safer and more efficient workplace. This does not mean that the manufacturer can eliminate all risk. The manufacturer must identify and communicate any residual risk to the end user.