ISO 12100 is a standard that defines the fundamental terminology and leads us to design a more reliable and safe machine by showing a structured methodology for risk assessment and risk reduction. All this knowledge comes from design experience, past accidents, risks associated with machinery, etc.

For the preparation of a proper risk assessment, the following related standards can be used:

  • ISO 14121-2 — Practical guidance and examples of methods
  • IEC 60204-1:2005 — Safety of machinery: Electrical equipment of machines

5-Step Strategy for Risk Assessment and Risk Reduction

  1. Determination of the limits of the machinery
  2. Identification of the hazards and associated hazardous situations
  3. Estimation of the risk for each identified hazard and hazardous situation
  4. Evaluation of the risk and decisions about the need for risk reduction
  5. Elimination of the hazard or reduction of the risk by means of protective measures

Step 1: Determination of the Limits of the Machinery

Determination of the limits of the machinery

Step 2: Hazard Identification

Hazard identification is the essential step in any risk assessment for reasonably foreseen hazards and hazardous situations throughout the complete life time of the machine.

Key considerations:

  • Human interaction during the whole life cycle (transport, assembly, installation, operation, maintenance)
  • All modes and functions of the machine (normal operation, emergency stop, cleaning)
  • Possible machine states: normal operation, malfunction (wrong workpiece, external effect, design errors, failed part)
  • Unintended behaviour of the operator (loss of control, carelessness, reflex in failure scenarios)

Step 3: Risk Estimation

After hazard identification, elements of risk must be determined for each hazardous situation.

Risk is a function of:

  • The severity of the harm
  • The probability of occurrence of that harm

Risk estimation

Aspects to be considered during risk estimation

At the conclusion of the risk estimation phase, risk evaluation and risk reduction phases must be carried out. ISO 12100 gives the fundamental methodology for risk assessment to assist designers.

Emrah Demirezen — Metal Forming Expert & Press Designer
info@demirezenengineering.com