Machinery Safety Assessment
Machinery Safety Assessment – safeguard your manufacturing facility by turning safety into an asset, not just an obligation.
Our Machinery Safety Assessment Service
We specialize in comprehensive Machinery Safety Assessment based on the ISO 12100 methodology. This ensures our services meet all requirements of the EU Machinery Directive 2006/42/EC and the new Machinery Regulation (EU) 2023/1230, as well as other relevant harmonized standards. In practice, this means that after our audit, your machinery not only complies with all applicable legal requirements but also achieves a higher level of user safety and operational efficiency – of course, provided that the audit recommendations are implemented.
Who Is This Service For?
Our machinery safety audit service is designed for a broad range of industrial clients. Manufacturing companies across various sectors will find the audit valuable, especially when implementing new production lines or integrating new machines into their facilities. Machine manufacturers and engineering design offices can also benefit from an independent verification – an audit will confirm that their products meet essential safety requirements before market release. In fact, any company aiming to uphold the highest safety standards and avoid workplace accidents should consider regular safety audits. It’s an investment in production continuity, reduced downtime, and a strong safety culture within the enterprise. (Note: While our focus is on EU compliance, we also assist companies outside the EU – for example, from the USA or Canada – who need support in meeting European safety requirements when supplying machinery to the EU market.)
Purpose of a Machinery Safety Audit
A Machinery Safety Assessment is a detailed evaluation process that identifies and analyzes potential hazards associated with industrial machines and production processes. The primary goal is to ensure that machines are safe to use and fully compliant with applicable regulations and standards. In conducting an audit, we follow the structured approach defined in ISO 12100, which entails systematic hazard identification, risk assessment, and risk reduction. As a result, the audit doesn’t stop at merely listing non-conformities – it focuses on recommending effective ways to eliminate dangers or reduce risks to an acceptable level.
Audit Methodology
Our audit process begins with a thorough review of the available machine documentation, such as technical files, schematics, operating manuals, and any existing risk assessment reports. This preparation helps us understand the specifics of your machinery and processes even before we set foot on site. The next step is an on-site inspection – during the visit, our auditor not only checks the condition of the machine but, most importantly, observes the actual production process in action. This real-world observation enables us to pinpoint potential hazards in the context of how the machinery is truly used.
After identifying hazards, we analyze each one using established risk assessment methods (for example, the risk-score method), evaluating the probability of occurrence and the potential consequences if an accident were to happen. Every identified risk is given a rating, and in the subsequent step we plan risk reduction measures in accordance with the three-step hierarchy outlined in ISO 12100: first, design out or eliminate the hazard; if that’s not possible, implement technical protective measures (guards, safety interlocks, light curtains, etc.); finally, apply appropriate administrative measures such as training and warning signs.
Our approach vs. a typical audit: Many routine audits are limited to ticking off a checklist of missing guards or sensors, ending with a simplistic recommendation like “install a guard as required by Standard X.” Our audits go a step further. A key element is our in-depth observation of your process – we ask questions such as: Will the proposed guard hinder the operator’s work? Could an added sensor cause unwanted downtime? We evaluate each recommendation in terms of its practical feasibility and impact on production continuity. This way, instead of theoretical advice, you receive solutions tailored to your plant’s reality – measures that enhance safety without undermining productivity.
An important aspect of our methodology is also analyzing the consequences of proposed changes in light of current regulations. We pay attention to whether the recommended modifications might qualify as a “substantial modification” of the machine under Machinery Regulation (EU) 2023/1230. The new rules clarify that a significant change to a machine (physical or digital) after it has been put into service – one that introduces new or increases existing hazards and requires additional protective measures – can be considered a substantial modification. Such a change entails the need for a renewed conformity assessment and effectively puts the modifier in the manufacturer’s role with respect to legal obligations. Our audit helps you recognize these situations in advance – so you’ll know whether your planned improvements will require extra procedures (like issuing a new EU Declaration of Conformity) or if they fall within the scope of a routine upgrade. This approach protects you from unknowingly assuming the responsibilities of a machine manufacturer without meeting formal legal requirements.
Your Benefits
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Improved safety culture
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Increased safety and compliance
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Process optimization and efficiency
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Avoiding costly downtime and fines
Conducting a Machinery Safety Assessment translates into tangible business benefits. Below are the key advantages:
Improved safety culture: Implementing audit recommendations and involving your workforce in safety improvements raises overall safety awareness. A company that regularly audits and upgrades its machines builds employee confidence that safety is a true priority. Over time, this strong safety culture leads to better teamwork, lower staff turnover, and a positive reputation for the business in the market.
Increased safety and compliance: The audit provides a roadmap to improve safety and verifies whether your machines meet all applicable laws and standards. This minimizes the risk of accidents and potential legal penalties. You gain peace of mind that the health and lives of employees are not exposed to unacceptable hazards.
Process optimization and efficiency: Identifying and eliminating sources of danger often goes hand-in-hand with streamlining machine operation. A safer machine tends to have a lower likelihood of failures and unplanned stoppages, which means greater production continuity and higher productivity. Additionally, implementing improvements can enhance ergonomics and operator comfort.
Avoiding costly downtime and fines: An audit can catch non-compliances early, before they lead to an accident, breakdown, or inspection citations. Proactive corrective actions help prevent expensive downtime and potential fines for regulatory violations. An independent audit report also serves as evidence of your commitment to safety, which can be valuable during external inspections or audits.
After the Audit – Long-Term Support and Development
Completion of the audit is just the beginning of the journey toward improved safety. As part of our service, we provide clients with comprehensive post-audit support. After delivering the audit report, we discuss all findings and recommendations in detail to ensure the corrective action plan is fully understood. Then we offer assistance in implementing the audit recommendations – from simple fixes to advanced modernization projects. In practice, this may include, among other things:
- Updating technical documentation: Preparing or updating missing documents (such as user manuals, safety schematics, risk assessments, etc.) so that all documentation reflects the machine’s new state and remains compliant.
- Designing and implementing safety solutions: Our engineering design office can support you in designing the required guards, fencing, safety interlocks, or safety control systems. We make sure the proposed protective measures are effective and seamlessly integrated into your existing production system.
- Modification project management: We take on the coordination of larger initiatives needed to bring your machinery park up to standard. Our experienced engineers oversee the safety retrofit or upgrade work from start to finish, ensuring everything proceeds on schedule and adheres to the highest quality standards.
- Post-modification compliance verification: After implementing the changes, we can perform a follow-up risk assessment to check that the introduced measures have indeed eliminated or mitigated the hazards. The final step can include assistance with carrying out the conformity assessment procedure for the modified machine (if it was a substantial modification) and preparing the documentation required for CE marking of the updated equipment.
With this end-to-end approach, you are not left alone with a list of recommendations – you gain a partner who helps turn the audit findings into concrete actions that enhance safety. Our goal is the long-term development of your safety culture – which is why even after implementations are completed, we remain available to advise on maintaining the achieved safety level and pursuing further improvements.
Machinery Safety Audits and ISO 12100
The foundation of our audits is ISO 12100 – an international standard that defines the general principles of risk assessment and risk reduction for machinery. This standard establishes key terminology related to machine safety and describes a structured approach to hazard identification and the implementation of appropriate protective measures. By utilizing the guidance of ISO 12100, our audits are built on solid scientific and legal underpinnings. In practice, this means that during a machine evaluation, step by step we:
- Identify hazards: We examine the machine and its environment for all potential dangerous events (mechanical, electrical, ergonomic, etc.).
- Assess the risks: For each identified hazard, we estimate the level of risk by considering the likelihood of occurrence and the possible severity of harm. This analysis helps determine which risks are the most serious.
- Reduce the risks: We propose measures to eliminate the hazard at its source or – if elimination is impossible – to reduce the risk to an acceptable level. In doing so, we apply the three-step method: first, safe design (e.g. remove the hazard through a design change), then technical safeguards (guards, interlocks, light curtains, etc.), and finally user information (instructions, warnings and training).
Basing the audit on ISO 12100 ensures a comprehensive approach to safety – covering the machine’s entire lifecycle from design and installation through operation, maintenance, and eventual modifications. Thus, our clients receive a report that not only points out non-compliances but also educates their team on industry best practices for designing and operating safe machinery. praktyk projektowania i eksploatacji bezpiecznych maszyn.
FAQ: Machinery Safety Assessment
A machinery safety audit is a detailed assessment of the condition of machines in a facility with respect to compliance with safety regulations and standards. During an audit, potential hazards associated with operating the machines are identified, and the conformity of existing technical solutions is evaluated against current requirements (for example, ISO 12100 and other applicable standards). The outcome of an audit is a report highlighting any non-conformities and providing improvement recommendations, which helps increase workplace safety and ensure legal compliance.
Regular safety audits allow you to detect and correct issues before they lead to an accident or equipment failure. An audit gives you confidence that your machines are safe for users and meet all applicable regulations. This is not only about protecting people – it’s also about avoiding downtime, financial penalties, and damage to your company’s reputation. In short, an audit is an investment that provides peace of mind and stability in your operations.
To facilitate a smooth audit, it’s best to prepare a complete set of up-to-date documents for the machines in question. Essential documentation includes each machine’s technical files (schematics, drawings, manuals), operating and maintenance instructions, maintenance and inspection logs, as well as any existing risk assessments. It’s also useful to have the EC/EU Declaration of Conformity for each machine (the CE marking certificate). The more complete the documentation, the more precisely and quickly the auditor can assess the machine’s compliance with requirements.
The duration of an audit depends on the number and complexity of machines, as well as the scope of the review. For a single, not overly complex machine, an audit might be completed in 1–2 days. If we are auditing an entire facility with multiple production lines, the process can take anywhere from several days to a few weeks. We always strive to adapt the audit schedule to your plant’s production rhythm to minimize any impact on operations. After an initial consultation, we will work with you to establish a plan and an approximate timeline for all necessary audit activities.
Strictly speaking, laws do not explicitly require periodic machine audits by external companies – the responsibility for ensuring machine safety lies with the employer and machine user. A safety audit is a voluntary preventative measure that helps fulfill this duty. In practice, many companies choose to conduct audits to make sure they comply with occupational safety regulations, the Machinery Directive, and other rules. In some cases, an audit can become virtually mandatory – for instance, after a serious accident, authorities might demand proof that your other machines are safe. Rather than waiting for such circumstances, it’s better to act proactively and audit your machines regularly.
If we identify any non-conformities or hazards during the audit, these will be detailed in the report. You will receive a list of issues along with an explanation of each problem (e.g. missing guard on a moving part, a faulty emergency stop switch, outdated instructions, etc.). For every non-compliance, we provide corrective action recommendations – concrete solutions needed to eliminate the hazard. We also prioritize the actions, indicating which issues require immediate intervention versus which can be scheduled later. Then, if you wish, we can assist in implementing the recommendations (machine modifications, training, documentation updates, etc.). The goal is to bring the machines into full compliance and ensure safe operation.
Yes. Comprehensive post-audit support is a crucial part of our offering. We don’t just hand over the report – we help you implement all the recommendations. We offer engineering consultations, technical design services (for example, designing and installing missing guards or implementing safety systems), and even full turnkey execution of necessary upgrades. In addition, we can train your employees on new procedures or on how to operate the newly implemented safety measures. We want to make sure that the audit’s recommendations lead to real improvements in safety, so we support you until that goal is achieved. In the long term, we remain available for advice and are ready to assist with future safety-related projects.
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