With the push of a button, the machine starts moving. For the operator, this means productivity, but also potential hazards. To ensure that routine does not turn into a risk, a clear understanding of every detail is essential: the risk assessment.
Relation to UL
The risk assessment considers all hazards associated with a machine, ranging from mechanical to electrical risks. This is precisely where UL certification comes into play: It confirms that control cabinets have been tested according to strict international standards and that electrical hazards are reliably controlled. One example is UL 508A. For us at Krayer, this means that our control cabinets are not only part of a legally required risk assessment but also support and ensure it through verifiably tested quality.
What does risk assessment mean?
A risk assessment is a systematic process in which all hazards associated with a machine are identified, evaluated, and controlled. The goal is to minimize risks early on by implementing appropriate measures, whether through design solutions, protective devices, or instructions in the user manual. It forms the basis for the CE marking and ensures that machines can be operated safely, reliably, and in compliance with standards.
Keeping an Eye on Risk
In the context of machinery, “risk” refers to the combination of the probability of an injury occurring and the severity of that injury. The more likely an injury is to occur, or the more serious its consequences are, the higher the risk. For manufacturers and designers, this means that risks must be identified early on and specifically minimized—through safe design, technical safeguards, or clear information for operators and maintenance personnel.
Risk Assessment Under the Machinery Directive
Machinery may only be placed on the market if all relevant risks have been identified, assessed, and controlled. This requirement is mandated by law (Machinery Directive 2006/42/EC) and forms the basis for the CE marking. A systematic risk assessment protects operators, machinery, and companies, ensures reliability, and makes safety measures transparent. It is therefore an essential component of modern machine safety.
When must a risk assessment be conducted?
A risk assessment is always required when a machine is newly developed, significantly modified, or placed on the market for the first time. It is also necessary when multiple machines are combined to form a complete system, when machines are imported from non-EU countries, or when safety deficiencies are identified in an existing machine. The goal is to systematically identify potential hazards at every stage of a machine’s life cycle and to minimize them through appropriate measures.
Who is responsible for risk assessment?
As a key component of plant safety, risk assessment requires clearly defined responsibilities so that all hazards can be identified and controlled at an early stage.
Machinery Manufacturers and Authorized Representatives
The primary responsibility lies with the machine manufacturer or its authorized representative. They must ensure that sufficient expertise, personnel, and resources are available to conduct the risk assessment thoroughly.
Design Engineers’ Expertise
In practice, it is usually the designers and developers who prepare the risk assessment. They know the machine and its components best and can identify risks early on and assess them accurately.
Support Through Documentation
Staff members such as technical writers can assist with documenting the risk assessment. However, the actual assessment of hazards and the determination of protective measures remain the responsibility of the experts.
The Purpose of Responsibility
This clear structure of responsibility ensures that risks are identified, assessed, and effectively controlled at an early stage. This is a key step in bringing machines to market safely and in compliance with standards.
Risk Assessment: Components and Process
A risk assessment takes into account all factors that affect a machine’s safety. Only by knowing which elements need to be examined can risks be effectively identified and reduced.
Set Machine Limits
First, the intended use of the machine and the conditions under which it will be operated are defined. This includes the scope of use, typical operating conditions, and the work environment. This information forms the basis for identifying hazards in a targeted manner.
Identify Hazards
The next step is to list all potential hazards: mechanical risks, electrical hazards, ergonomic stresses, as well as thermal, chemical, and environmental factors. The goal is to obtain a complete picture of all risks that may be posed by the machine.
Assessing and Evaluating Risks
Each identified hazard is assessed in terms of the severity of the damage and the likelihood of occurrence. This assessment helps identify the most critical risks and set priorities for protective measures.
Develop measures
Based on the risk assessment, targeted measures are developed to minimize risks. These include inherently safe design, technical safeguards, and user information, which together ensure that the machine can be used safely and reliably.
Create Documentation
Each step of the risk assessment is carefully documented. The documentation serves as evidence of CE conformity, supports product liability, and forms the basis for continuous improvement.
Limits of Acceptable Risk
Not all risks can be completely eliminated. That is why it is crucial to determine when a risk is still considered acceptable.
What determines the limit?
Determining whether a risk is acceptable depends on various factors: the severity of the potential harm, the frequency of occurrence, the technical feasibility of protective measures, and the operators’ level of knowledge.
Who sets the limit?
The machine manufacturer is generally responsible. Based on standards, guidelines, and best practices, the manufacturer determines which risks are acceptable. Regulatory agencies, testing organizations, or customer requirements may also influence this determination.
Purpose of the Risk Measure
The goal is to reduce risks as much as possible without making the machine impractical or technically unfeasible. Any remaining residual risks must be documented and controlled through user information or safety measures.
Legal Framework and Standards
Risk assessment is not only a technical requirement; it is also mandated by law and clearly structured by standards. Anyone who wants to design machinery safely and in compliance with standards must understand which rules apply and how they are implemented.
Risk Assessment as a Legal Requirement
Machinery may only be placed on the market if all relevant risks have been identified, assessed, and controlled. This obligation is enshrined in the Machinery Directive 2006/42/EC and forms the basis for the Declaration of Conformity and the CE marking. The risk assessment ensures that the safety, health protection, and reliability of machinery are systematically guaranteed.
Standards as a Guide for Implementation
ISO 12100 describes how hazards are identified, risks are assessed, and measures are determined. It is supplemented by other standards, such as ISO 13849-1 for safety-related control systems or specific Type C standards for certain types of machinery. Together, these standards provide a clear framework for every risk assessment.
UL Certification as Additional Proof of Safety
Legal requirements and standards form the basis for safe machinery. UL certification goes a step further and verifies that control cabinets are manufactured in accordance with the most stringent international standards. It confirms that risks are systematically controlled and electrical hazards are reliably managed. UL certification thus complements the legally required risk assessment and provides companies with visible proof of verified safety and quality.
Zusammenfassung
Die Risikobeurteilung ist der Schlüssel zu sicheren Maschinen. Sie sorgt dafür, dass alle Gefährdungen erkannt, bewertet und wirksam kontrolliert werden. Normen, gesetzliche Vorgaben und die UL-Zertifizierung liefern dabei Orientierung und Nachweis für geprüfte Sicherheit. So wird aus einem Risiko ein beherrschbares Element, das Bediener, Maschinen und Unternehmen schützt.
