Machine Safety: Key Aspects and Practices

Machine safety is one of the most important aspects of modern industry. Without appropriate safeguards, both workers and production processes are exposed to the risk of failures and accidents. In this article, we discuss the key aspects of machine safety, best practices, and the regulations that help ensure a safe working environment.

Machine safety: the basics

Machine safety encompasses a set of measures and practices aimed at preventing accidents and minimizing the risks associated with machine use. The Machinery Directive 2006/42/EC provides the legal basis for machine safety in the European Union, setting out requirements for the design, manufacture, and use of machinery.

Industrial automation has a major impact on machine safety. On the one hand, automation increases efficiency, but on the other, it can introduce new hazards. For example, automated production lines can lead to serious accidents if they are not properly safeguarded. That is why a safety audit is essential to identify potential risks and implement preventive measures.

Audit and risk assessment

A safety audit is a key part of evaluating risks associated with machinery. Companies such as ours specialize in carrying out audits that help identify potential hazards and implement appropriate preventive measures. Risk assessment according to EN ISO 12100 is a widely used method for identifying and assessing risk at different stages of a machine’s life cycle.

Design offices ensure safety as early as the machine design stage, as well as during the design of production lines. This means not only applying the relevant standards, but also carrying out detailed strength calculations (FEA) and other numerical analyses that support safe design. This helps prevent failures and accidents during operation.

Machine safety: CE certification and machine adaptation

Conformity assessment procedure

The CE certification process for machinery (an informal term; the correct term is the machinery conformity assessment process) is necessary for machinery to be legally placed on the European Union market. This is the formal procedure for assessing compliance with the Machinery Directive 2006/42/EC and applying the CE mark. The conformity assessment procedure consists of several stages:

1. Identification of applicable requirements: First, it is necessary to identify which directives and harmonized standards apply to the machine in question.
2. Risk assessment: The manufacturer must carry out a risk assessment in accordance with EN ISO 12100. This process includes identifying potential hazards, assessing risk, and determining appropriate preventive measures.
3. Technical documentation: The manufacturer must prepare detailed technical documentation, including technical drawings, electrical schematics, strength calculations, test reports, operating instructions, and the declaration of conformity.
4. Declaration of conformity and CE marking: Once all requirements have been met, the manufacturer prepares the EC declaration of conformity, confirming that the machine meets all applicable requirements. The machine is then marked with the CE mark.
5. Document retention: The manufacturer is required to retain the technical documentation for at least 10 years from the date the last unit of the machine was manufactured.

Risk assessment

Risk assessment is a key element in ensuring machine safety. This process includes the following stages:

1. Hazard identification: At this stage, all potential hazards associated with use of the machine are identified, such as mechanical, electrical, thermal, chemical, and other hazards.
2. Risk assessment: Next, the likelihood of each hazard occurring and its potential consequences are assessed. Risk is classified on the basis of these two factors.
3. Preventive measures: Based on the risk assessment, appropriate preventive measures are defined to eliminate or minimize the risk. These may include technical, organizational, or procedural measures.
4. Verification: After the preventive measures have been implemented, verification is carried out to ensure that the risk has been effectively reduced. If necessary, the risk assessment process is repeated until an acceptable level of safety is achieved.

Machine safety: Machine adaptation and minimum requirements

Work equipment directive

Adapting older machines to minimum requirements is essential to ensure compliance with current safety standards. Some machines that were in use before the introduction of the Machinery Directive 2006/42/EC may require additional measures to bring them into line with current standards. Adapting machines to minimum requirements includes:

1. Review and assessment of technical condition: Carrying out a detailed technical analysis of the machine to assess its current condition and identify areas that require modernization.
2. Physical modernization: Introducing the necessary changes and upgrades to the machine design, such as installing guards, safety systems, interlocks, and other protective devices.
3. Documentation update: Preparing or updating the machine’s technical documentation, including operating instructions, electrical and mechanical diagrams, and documentation related to the risk assessment.
4. Personnel training: Providing appropriate training for operators and personnel working with the machine on new procedures and safety measures.

Work equipment directive 2009/104/EC

Directive 2009/104/EC, also known as the directive on the use of work equipment by workers, sets out the minimum safety requirements for the use of work equipment. The purpose of this directive is to ensure that work equipment, including machines, is used safely and for its intended purpose. The minimum requirements include:

1. Design safety: Work equipment must be designed and constructed to ensure safe use. This applies to both new and used equipment.
2. Instructions and training: Employers are required to provide workers with clear operating instructions and appropriate training in the safe use of work equipment.
3. Regular inspections and maintenance: Work equipment must be regularly inspected, maintained, and tested to ensure proper operation and safety.
4. Personal protective equipment: Employers must provide workers with appropriate personal protective equipment (PPE), such as helmets, gloves, and safety glasses, where required.
5. Ergonomics: Work equipment should be designed in accordance with ergonomic principles to minimize the risk of injury resulting from improper use or excessive physical strain on workers.

Implementing the requirements arising from the work equipment directive, and properly adapting machines and work equipment to current standards, is essential to ensuring a safe working environment. Compliance with these regulations helps minimize the risk of accidents and protect workers’ health, which is a fundamental element of effective safety management in industry.

Machine safety: Design and project management

Machine design with a strong focus on safety is the foundation of a safe working environment. From the concept stage, design offices ensure that machines and production lines are safe, including through risk assessment according to EN ISO 12100. Project management plays a key role in developing new solutions. The client has a defined budget, and the solutions must be safe. Cooperation between the client and supplier is essential to finding a compromise between expectations and real-world constraints.

When designing machines, engineers must consider not only performance but also user safety. This means applying the relevant standards, such as harmonized standards, and taking into account the results of risk analysis according to EN ISO 12100. This makes it possible to identify and manage risk at the design stage, which significantly improves the safety of the final product.

Industrial automation and new technologies

Industrial automation has a major impact on machine safety. Although automation can increase efficiency, it also introduces potential hazards. Industry 4.0 brings in new technologies that can improve machine safety, but it also requires a new approach to risk management.

PLC programming (Programmable Logic Controller) is a key element in automating industrial processes. With proper programming, it is possible to create safe and reliable control systems that minimize the risk of failures and accidents. Industrial automation integrators play a key role here, ensuring that all system components work together safely and efficiently.

Engineering support and outsourcing

Engineering outsourcing is an effective way to ensure a high level of safety from the concept stage of new machines and production lines. Working with a design office and industrial automation integrators can significantly improve the safety and efficiency of production processes.

Through engineering outsourcing, companies can draw on the knowledge and experience of specialists who help create safe machines and production lines. This is particularly important in the context of new technologies and production process automation, where advanced skills and expertise are required.

Project management and the cost of safety

Project management is a key part of the process of developing new machines and production lines. It is worth remembering that safety comes at a cost, but cutting costs at the expense of workers’ health and lives is not an option. That is why risks must be identified and managed at every stage of the project. Cooperation between the client and the supplier is essential to find compromises between safety requirements and budget constraints, and realistic budgeting for CE certification can help avoid unnecessary costs.

Harmonized standards and legal requirements

Harmonized standards play a key role in ensuring machine safety. Compliance with these standards is essential for obtaining the CE mark and CE certification for machines. Machinery Directive 2006/42/EC and other legal requirements define the minimum conditions that must be met before machines can be placed on the EU market.

Industry 4.0 and the future of machine safety

Industry 4.0 introduces new technologies such as the Internet of Things (IoT), artificial intelligence (AI), and robotics, which can significantly improve machine safety. Modern monitoring and diagnostic systems can detect potential failures before they occur, enabling a proactive approach to risk management.

The role of operating instructions and training

In addition to the technical aspects of safety, proper employee training and the provision of clear operating instructions are also essential. Training should cover both the theoretical and practical aspects of machine operation, including how to respond in emergency situations.

Machine safety is a complex, multifaceted issue that requires a holistic approach. Compliance with regulations, conducting audits, proper design and project management, as well as the use of modern technologies and engineering outsourcing, are all essential. Only a comprehensive approach to machine safety can ensure a safe and efficient working environment in modern industry.

Machine safety management requires cooperation between different departments.