Why is risk assessment a key part of safety?

Safety in the workplace is a top priority from the moment an employee arrives at the site and must be guaranteed until they return home safely. Human life and health must come first.  Safety between machines and people can be ensured by developing competence and using risk analysis tools.

Internationally approved standards form the basis for managing risks related to machine safety. One of the most important standards is EN ISO 12100, which presents general principles for assessing and minimising risks in machines.

The aim of the standard is to promote the safe design of machines throughout their life cycle and to ensure the consistency and effectiveness of safety measures.

Although compliance with the standards is voluntary, they enable the manufacturer to demonstrate that the machine complies with the requirements set out in the Directive and, subsequently, in Regulation 2023/1230.

Machine safety covers a wider range of issues than just physical protection solutions such as protective covers and emergency stop buttons. It also includes the safety of machine control systems, the preparation of operating instructions, user training and safety rules for maintenance.

Today, machine safety also covers the areas of digital systems and cybersecurity. This development is a result of more and more machines being connected to the network. In this case, new threats may arise and safety practices need to be expanded.

The EN ISO 12100 standard defines methods for identifying, analysing, evaluating risks and reducing them to an acceptable level. The method covers the entire life cycle of a machine, from its design, use and maintenance to its disposal. The aim is to ensure that no risks are overlooked and that appropriate measures are taken to eliminate them. Risk assessment is not only a technical obligation, but also a legal and administrative practice. A thoroughly documented risk assessment serves as proof of compliance with legal requirements and ensures continuous improvement in safety. It helps to ensure that designers, manufacturers and users work towards common safety goals throughout the entire life cycle of the machine.

Risk analysis should always be a priority, as it allows problems to be anticipated before they arise.

The first step in risk analysis is to define the limits of the machine's capabilities -  determining the intended use of the machine, its technical characteristics, operating conditions and any exceptional situations. Defining the limits is important for understanding the machine's working environment and the hazards associated with it.

Once the hazards have been identified, a risk assessment is carried out to determine the magnitude of the risk.

The severity of the potential harm and the likelihood of its occurrence are two key factors in determining the magnitude of the risk. Severity refers to the degree of physical or health damage, while likelihood assesses how easily a hazardous situation can occur. The magnitude of the risk is determined on the basis of these factors, after which an assessment is made as to whether the risk can be accepted as it stands or whether it needs to be reduced.

According to EN ISO 12100, risk assessment is not a one-off activity, but a continuous and iterative process. If the risk is unacceptable, the machine designer must take measures to reduce it. The primary objective is to completely eliminate the hazard. If the hazard cannot be eliminated, technical protective measures are used to control it. This is followed by warnings, instructions and training.

Risk assessment consists of two stages: risk analysis and risk evaluation. Risk evaluation requires comprehensive information, including information on the design of the machine, its life cycle at different stages, applicable regulations and standards, previous operating experience such as accidents or failures, and future changes to the machine. Information and results related to risk assessment must be properly recorded in accordance with the requirements of the standard.