The objective of risk reduction can be achieved by eliminating hazards or reducing, either individually or simultaneously, each of the two elements of risk:
- the severity of damage caused by the hazard under consideration;
- probability of damage occurrence.
Actions aimed to achieve this objective should be taken in a specific order:
- Application of inherently safe design solutions, eliminating hazards or reducing the associated risks by appropriate selection of the design characteristics of the machine itself and/or interaction of exposed people and the machine. As a result of these actions the hazard can be eliminated, which makes it unnecessary to use additional protective measures.
- Application of engineering control measures and/or complementary protective measures when it is not feasible to eliminate the hazard or reduce the associated risks to a sufficient degree with the use of inherently safe design solutions.
- Information on the use, if the risk remains despite the use of inherently safe design solutions, engineering control measures and/or complementary protective measures. Information concerning the use should include information on residual risks identified. This information should not be considered as a measure replacing the correct application of the above inherently safe design solutions and engineering control measures or complementary protective measures.
Adoption of these measures should lead to achieving a sufficient risk reduction, i.e. the condition in which:
- all types of work and methods of interaction are taken into account;
- all hazards are eliminated or risks caused by them are reduced to the lowest level possible in practice;
- all new hazards that have emerged along with the protective measures are properly demonstrated and appropriate protective measures are used;
- users are fully informed and warned of residual risks;
- mutual compatibility of protective measures used is achieved;
- the consequences are sufficiently taken into account, if the machine designed for professional/industrial use is used for non-professional/non-industrial purposes;
- protective measures taken do not adversely affect the working conditions of the operator or the usefulness of the machine.
Protective measures must permit easy use of machines in accordance with their intended purpose, so that users do not attempt to defeat or circumvent the actions of those measures. Such actions may occur when a safety measure:
- slows down the production process;
- conflicts with another activity;
- interferes with the user’s preferences;
- is difficult to use;
- engages persons other than the operator;
- is not recognised by the user;
- is not accepted by the user as appropriate to the intended function.
The following definitions are used for risk assessment [1].
Reducing the risk to a level that – taking into account the current state of the art – is at least at the level required by law.
A measure designed to reduce the risk, used by:
- the designer (inherently safe design solutions, engineering control measures and complementary protective measures, information on the use); and/or
- the user (organisation of: safe working methods, surveillance, permit to work systems, provision and use of additional engineering control measures, use of personal protective equipment, training).
A safeguard, which either eliminates the hazards or reduces the associated risk, changing the machine design or operating characteristics without the use of guards or safety devices.
Protective measures such as guards or safety devices used to protect people from hazards which cannot be reasonably eliminated, or applied in the case of risk which cannot be reduced with the use inherently safe design solutions.
Physical barriers designed as part of a machine intended to provide protection.
Guards can work:
- independently – in this case they are only effective when closed (like movable guards) or when they are secured in place (like fixed guards); or
- in combination with an interlock with or without locking.
Inherently safe design solutions eliminate hazards or reduce the risk by appropriate selection of the design characteristics of the machine itself and/or interaction of people exposed and the machine.
Considering the use of the machine in accordance with the intended purpose and foreseeable inappropriate use, engineering control measures or complementary protective measures are used to reduce the risk when it is not possible to eliminate the hazard or sufficiently reduce the associated risk using inherently safe design solutions.
Information on the use, in terms of identified residual risks, should include in particular:
- machine operating procedures appropriate for the personnel who will operate the machine or other persons potentially exposed to the hazards posed by the machine;
- recommended safe methods to use the machine and related requirements for required training;
- relevant information, including a warning about residual risks occurring at different stages of machine life;
- description of the recommended personal protection equipment, stating the necessity for its use and provision of training in its use.
Table 1.1. Geometrical characteristics of machines and their impact on safety
|
Item |
Taking into account geometrical characteristics of the machine |
Impact on safety |
Method of implementation |
|
1 |
Shape of the machine |
The highest possible direct visibility of work areas and hazard zones from the operator workstation. |
· reduction of invisible spots; · selection and placement of devices for indirect vision (e.g. mirrors); · consideration of the possibility of view of the operator to supervise: - movement and operation of mobile machines, - movement of loads being lifted or machine carriers for lifting people, - contact of a tool with the workpiece hand-held or hand-guided, - presence of people in hazardous zones. |
|
Reduction of the ergonomic risk |
· enable the operator to maintain a proper operating position; · allow appropriate access to control elements. |
||
|
2 |
Shape and position relative to each other of machine mechanical components |
Reducing the risk of injuries (e.g. by crushing or cutting) |
· increasing the smallest distances between moving parts in order to maintain safety when the body part concerned is located in the designed space; · reducing the distance between moving parts such that no body part could be found in them [2]. |
|
3 |
User-accessible machine edges and corners |
Reducing the risk of injuries (by impact, cutting or dismembering) |
· avoiding sharp edges and corners; · avoiding protruding parts; · avoiding rough surfaces; · avoiding protruding parts; · avoiding openings which are hazardous to a body part or garment. |
Taking into account the geometric characteristics should lead to improving the safety of the machine. Geometric characteristics to be taken into account when designing the machine and their impact on safety are presented in Table 1.1.
|
PN-EN ISO 12100:2012 PN-EN 547-3 +A1:2010 PN-EN 614-1+A1:2009 PN-EN 614-2+A1:2010 PN-EN 894-1+A1:2010 PN-EN 894-2+A1:2010 PN-EN 894-3+A1:2010 PN-EN 894-4+A1:2010 PN-EN 1005-1+A1:2010 PN-EN 1005-2+A1:2010 PN-EN 1005-3+A1:2009 PN-EN 1005-4+A1:2009 PN-EN ISO 14738:2009 PN-EN ISO 15536-1:2009 PN-EN ISO 7731: 2009 |
EN ISO 12100:2010 EN 547-3:1996+A1:2008 EN 614-1:2006+A1:2009 EN 614-2:2000+A1:2008 EN 894-1:1997+A1:2008 EN 894-2:1997+A1:2008 EN 894-3:2000+A1:2008 EN 894-4:2010 EN 1005-1:2001+A1:2008 EN 1005-2:2003+A1:2008 EN 1005-3:2002+A1:2008 EN 1005-4:2005+A1:2008 EN ISO 14738:2008 EN ISO 15536-1:2008 EN ISO 7731:2008 |
Physical characteristics of the operator to be taken into account when designing the machine and their impact on safety are presented in Table 1.2.
Table 1.2. Physical characteristics of the operator and their impact on safety
|
Item |
Taking into account physical characteristics of the machine operator |
Impact on safety |
Method of implementation |
|
1 |
Operator’s force |
Reducing the operator force necessary to act on machine elements in order to reduce the risk of mechanical hazards |
· reducing the force required to start up the machine · reducing the weight and/or speed of moving parts |
|
2 |
Operator’s resistance to impact of machine elements |
Reducing the kinetic energy of machine parts causing a risk of injury |
· reducing the weight and/or speed of moving parts |
|
3 |
Operator’s resistance to exposure of work environment factors |
Reducing emissions from the machine by acting on the properties of their sources |
· reducing noise emissions at source (e.g. use of sound-absorbing materials) [3]; · reducing vibration emissions at source (e.g. redistribution or increase in weight, change of frequency and/or amplitude of the movements of machine parts); · reducing emissions of harmful substances (e.g. use of less harmful substances or processes which limit dust emission); · reducing radiation emissions (e.g. elimination of hazardous radiation sources, reduction of radiated power to the lowest level enabling proper machine function, increasing the distance between the radiation source and the operator). |
Machine characteristics resulting from general engineering knowledge to be taken into account when designing the machine and their impact on safety are presented in Table 1.3.
Table 1.3. Machine characteristics resulting from general engineering knowledge and their impact on safety
|
Item |
Taking into account machine characteristics resulting from general engineering knowledge |
Impact on safety |
Method of implementation |
|
1 |
Mechanical loads |
Reducing the risk of injuries caused by excessive load of machine parts |
· use appropriate methods of calculation; · use appropriate methods of building and connection; · preventing overload (e.g. use of fuses, pressure or torque reducing valves); · avoidance of fatigue of elements subjected to variable (e.g. cyclic) loads; · static and dynamic balancing of rotating parts; · use of safety factors for the calculation of machine part loads (if reliability of the parts or assemblies is critical for safety reasons). |
|
2 |
Properties of applied materials |
Reducing the risk of injuries caused by excessive wear or damage of machine parts |
· taking into account resistance to corrosion, ageing, abrasion and wear; · taking into account the hardness, ductility, brittleness; · taking into account the homogeneity; · taking into account the toxicity and flammability. |
Technologies matching the specified intended purposes of the machine to be taken into account when designing the machine and their impact on safety are presented in Table 1.4.
Table 1.4. Matching manufacturing techniques for the use of the machine and the effect on safety
|
Item |
Taking into account the selection of the technology for particular intended purposes of the machine |
Impact on safety |
Method of implementation |
|
1 |
Suitability for operation in explosive atmospheres or in fire hazard areas |
Reducing the risk of fire or explosion |
· use of fully pneumatic or hydraulic control system and drive elements; · use of intrinsically safe electrical equipment; · use of equipment for maintaining temperatures significantly below the flash point. |
|
2 |
Suitability for operation in an environment where there is a high exposure to noise |
Reducing the risk of noise emission |
· use of electrical equipment instead of pneumatic equipment; · use of equipment for waterjet cutting instead of mechanical equipment. |
Improvement of the machine operation reliability and therefore its safety can be achieved by applying the principle of mechanically forced interaction of its elements. In this case, a movable mechanical structural element moves another structural element by direct contact or through rigid elements. A typical example of such action is the forced opening of switching device contacts in a circuit by moving of mechanical parts.
Machine features ensuring stability to be taken into account when designing the machine and their impact on safety are presented in Table 1.5. Stability should be taken into account in all phases of the machine service life, such as: moving, driving, installation, operation, decommissioning and dismantling.
Table 1.5. Provision of machine stability under certain operating conditions and the impact on safety
|
Item |
Provision of machine stability under certain operating conditions of its application |
Impact on safety |
Method of implementation |
|
1 |
Ensuring appropriate stability to the application conditions |
Reducing the risk of injuries caused by machine roll over (risk of impact, compression, crushing injury) |
· taking into account the shape and dimensions of the machine base; · take into account the total weight distribution including the load; · taking into account dynamic forces forming the overturning moment caused by the movement of the machine and its parts or elements supported by it; · taking into account changes of the centre of gravity; · taking into account external forces (e.g. wind pressure and muscle strength); · taking into account vibrations which may cause a loss of stability; · taking into account the topography during the travel or machine foundation conditions (e.g. condition of the ground, slope). |
When designing the machine consideration should be given to factors which increase machine safety by improving its ease of operation. When designing the machine the following must be considered:
- ease of access, taking into account the environment and dimensions of the human body, taking into account the dimensions of work clothes and work tools used;
- ease of movement, taking into account human capabilities;
- limiting the number of special tools and special equipment to be used.
|
PN-EN ISO 12100:2012 PN-EN 547-3 +A1:2010 PN-EN 614-1+A1:2009 PN-EN 614-2+A1:2010 PN-EN 894-1+A1:2010 PN-EN 894-2+A1:2010 PN-EN 894-3+A1:2010 PN-EN 894-4+A1:2010 PN-EN 1005-1+A1:2010 PN-EN 1005-2+A1:2010 PN-EN 1005-3+A1:2009 PN-EN 1005-4+A1:2009 PN-EN ISO 14738:2009 PN-EN ISO 15536-1:2009 PN-EN ISO 7731: 2009 |
EN ISO 12100:2010 EN 547-3:1996+A1:2008 EN 614-1:2006+A1:2009 EN 614-2:2000+A1:2008 EN 894-1:1997+A1:2008 EN 894-2:1997+A1:2008 EN 894-3:2000+A1:2008 EN 894-4:2010 EN 1005-1:2001+A1:2008 EN 1005-2:2003+A1:2008 EN 1005-3:2002+A1:2008 EN 1005-4:2005+A1:2008 EN ISO 14738:2008 EN ISO 15536-1:2008 EN ISO 7731:2008 |
Observing the principles of ergonomics in the design of machines reduces the operator’s mental and physical load. The applied principles of ergonomics and their impact on safety are presented in Table 1.6.
Table 1.6. The application of the principles of ergonomics and their impact on safety
|
Item |
Principles of ergonomics |
Impact on safety |
Method of implementation |
|
1 |
Appropriate division of tasks between the operator and the machine |
Increasing operational reliability while reducing the likelihood of mistakes (leading to injuries) during the use of the machine |
· taking into account the degree of automation of the manufacturing process; · taking into account physical capabilities and working position; · taking into account the amplitude of movements, the frequency of cyclic actions [4,5,6]; · taking into account the appropriate interoperation between the machine and the operator (through use of comprehensible control elements, signalling elements and information elements to enable full and unambiguous cooperation between the operator and the machine [7,8,9] |
|
2 |
Reducing ergonomic nuisance related to the operation of the machine |
Reducing the risk of occurrence of musculo-skeletal disorders |
· avoiding awkward body positions and movements during machine operation (e.g. by adapting the machine to requirements of different operators); · ensuring easy operation of machines, taking into account human effort, activation of control elements and the anatomy of human limbs; · avoiding linking the rhythm of the operator’s work with the automatic cycle of the machine. |
|
PN-EN 12100:2012 PN-EN 60204-1:2010 PN-EN 60529:2003 |
EN ISO 12100:2010 EN 60204-1:2006+A1:2009 EN 60529:1991 |
|
PN-EN 12100:2012 |
EN ISO 12100:2010 |
In order to eliminate electrical hazards at source the requirements of PN-EN 60204-1 [10] concerning the design of electrical equipment must be complied with as well as the requirements of standards relating to special machines such as electric hand or portable power machines.
|
PN-EN 12100:2012 PN-EN ISO 4414:2011 PN EN ISO 4413:2011 |
EN ISO 12100:2010 EN ISO 4414:2010 EN ISO 4413:2010 |
In order to eliminate the hazards appropriate design of pneumatic and hydraulic equipment [11,12] is required. The issues to be taken into account when designing the machine and their impact on safety are presented in Table 1.7.
Table 1.7. Safety measures used to protect against the hazards arising from the use of pneumatic and hydraulic equipment and their impact on safety
|
Item |
Safety measures used to protect against the hazards arising from the use of pneumatic and hydraulic equipment |
Impact on safety of use of pneumatic and hydraulic equipment |
Method of implementation |
|
1 |
Increasing reliability of operation |
Reducing the risk of injury |
· use of pressure limiting devices (to prevent exceeding the allowable pressure); · preventing hazards arising from pressure fluctuations or increases; · preventing hazards arising from depressurisation, pressure decrease or loss of vacuum; · preventing risks arising from leakage or damage of components (hazardous ejection of fluid or hose whip); · meeting the requirements of regulations and rules concerning tanks; · securing pieces of equipment (pipes, hoses) against harmful work environment impacts; · ensuring pressure discharge in tanks (automatic) or fitting machines with means for disconnection, discharge and pressure monitoring; · equipping pressurised elements which remain under pressure after disconnecting the machine from the power supply with clearly identifiable triggering devices and a warning label (indicating the necessity to release pressure before starting setting or other activities related to the operation of the machine). |
|
PN-EN ISO 12100:2012 PN EN ISO 13849-1:2008 PN EN ISO 13849-2: 2013 PN-EN 62061:2008 |
EN ISO 12100:2010 EN ISO 13849-1:2008+AC:2009 EN ISO 13849-2:2012 EN 62061:2005 |
|
PN-EN 60204-1:2010 |
EN 60204-1:2006+A1:2009 |
The principles are set forth in the tab “Guards and protective equipment.”
|
PN-EN ISO 12100:2012 PN EN ISO 13849-1:2008 PN EN ISO 13849-2: 2013 PN-EN 62061:2008 |
EN ISO 12100:2010 EN ISO 13849-1:2008+AC:2009 EN ISO 13849-2:2012 EN 62061:2005 |
|
PN-EN 60204-1:2010 PN-EN 61310-3:2010 |
EN 60204-1:2006+A1:2009 EN 61310-3:2008 |
|
PN-EN 1037+A1:2010 |
EN 1037:1995+A1:2008 |
The principles are set forth in the tab “Guards and protective equipment.”
Mechanisation and automation of manual handling operations of workpieces, materials and substances reduce the risk of injuries and disorders related to these operations. The aspects of limiting manual handling operations to be taken into account when designing the machine and their impact on safety are presented in Table 1.8.
Table 1.8. Automation and mechanisation of handling operations and their effect on safety
|
Item |
Principles of ergonomics |
Impact on safety |
Method of implementation |
|
1 |
Automation and mechanisation of handling operations |
Reducing the risk of injuries and diseases related to manual handling operations |
· use of robots; · use of manipulators; · use of transfer devices; · use of blowers; · examination of automatic feeding and receiving devices with their own control systems should be coupled with the machine control system with regard to function of all safety features in all control methods and modes of operation of these devices. |
Places of machine setup and maintenance should be located outside the hazard zones.
Engineering control measures and complementary protective measures should be provided if an inherently safe solution fails to eliminate or insufficiently reduces a risk.
|
PN-EN 12100:2012 PN-EN 953+A1:2009 PN-EN 60529:2003 PN-EN ISO 13857:2010 PN-EN 349+A1:2010 PN-EN 547-1+A1:2010 PN-EN 547-2+A1:2010 |
EN ISO 12100:2010 EN 953:1997+A1:2009 EN 60529:1991 EN ISO 13857:2008 EN 349:1993+A1:2008 EN 547-1:1996+A1:2008 EN 547-2:1996+A1:2008 |
|
PN-EN 60529:2003 PN-EN ISO 13857:2010 |
EN 60529:1991 EN ISO 13857:2008 |
The principles are set forth in the tab “Guards and protective equipment.”
|
PN-EN 12100:2012 PN-EN 61496-1:2014 PN-EN ISO 13855:2010 |
EN ISO 12100:2010 EN 61496-1:2013 EN ISO 13855:2010 |
The principles are set forth in the tab “Guards and protective equipment.”
These measures are used if stability cannot be ensured using inherently safe design solutions. They include: anchor bolts, position retainers, movement restricters, mechanical stops, acceleration and deceleration limiters, load limiters and devices warning against exceeding a stability or overturning threshold.
Aspects of reducing operator mistakes and their effects to be taken into account when designing the machine are presented in Table 1.9.
Table 1.9. Reducing potential machine operator errors and their impact on safety
|
Item |
Reducing potential machine operator errors |
Impact on safety |
Method of implementation |
|
1 |
Use of devices to reduce operator errors |
Reducing the risk of injuries through the use of devices to maintain machine operation within specific “safe” limits. |
· reducing movement parameters (distance, angle, speed, acceleration); · protecting parts and assemblies against overload and excessive torque; · preventing collisions or adverse interactions of machines; · preventing risks for pedestrian operators driving walk behind mobile machines and for other pedestrians; · reducing the pressure or temperature; · supervising machine emissions; · preventing machine operation during the absence of the operator at a control station; · preventing the lifting operation with improper position of the machine stabilisers; · limiting the tilt of a machine positioned on a slope; · ensuring safe position of all components before starting to move the machine. |
|
PN-EN 12100:2012 PN-EN ISO 3741: 2011 PN-EN ISO 3743-1:2011 PN-EN ISO 3743-2:2010 PN-EN ISO 3744:2011 PN-EN ISO 3745: 2012 PN-EN ISO 3746:2011 PN-EN ISO 3747: 2011 PN-EN ISO 4871:2012 PN-EN ISO 5136: 2009 PN-EN ISO 7235: 2009 PN-EN ISO 9614-1: 2010 PN-EN ISO 9614-3: 2010 PN-EN ISO 11200: 2011 PN-EN ISO 11201:2012 PN-EN ISO 11202: 2012 PN-EN ISO 11203: 2010 PN-EN ISO 11204: 2010 PN-EN ISO 11205:2010 PN-EN ISO 11546-1: 2010 PN-EN ISO 11546-2: 2010 PN-EN ISO 11554: 2010 PN-EN ISO 11688-1: 2010 PN-EN ISO 11691: 2009 PN-EN ISO 11957: 2010 |
EN ISO 12100:2010 EN ISO 3741:2010 EN ISO 3743-1:2010 EN ISO 3743-2:2009 EN ISO 3744:2010 EN ISO 3745:2012 EN ISO 3746:2010 EN ISO 3747:2010 EN ISO 4871:2009 EN ISO 5136:2009 EN ISO 7235:2009 EN ISO 9614-1:2009 EN ISO 9614-3:2009 EN ISO 11200:2009 EN ISO 11201: 2010 EN ISO 11202:2010 EN ISO 11203:2009 EN ISO 11204:2010 EN ISO 11205:2009 EN ISO 11546-1:2009 EN ISO 11546-2:2009 EN ISO 11554:2008 EN ISO 11688-1:2009 EN ISO 11691:2009 EN ISO 11957:2009 |
|
PN-EN 1032+A1:2010 PN-EN 1299+A1:2010 PN-EN 1299+A1:2010 PN EN ISO 20643: 2009+A1:2012 PN EN 30326-1:2000 +A1:2008+A2:2012 |
EN 1032:2003+A1:2008 EN 1299:1997+A1:2008 EN 1299:1997+A1:2008 EN ISO 20643:2008+ A1:2012 EN 30326-1:1994+A1:2007 +A2:2011 |
|
PN-EN 12198-1+A1:2010 PN-EN 12198-2+A1:2010 PN-EN 12198-3+A1:2010 |
EN 12198-1:2000+A1:2008 EN 12198-2:2002+A1:2008 EN 12198-3:2002+A1:2008 |
|
PN EN ISO 11145:2010 PN-EN 12254: 2011 |
EN ISO 11145:2008 EN 12254:2010+AC:2011 |
|
PN-EN 626-1+A1:2010 PN-EN 626-2+A1:2010 PN-EN 1093-1: 2009 PN-EN 1093-2 +A1:2008 PN-EN 1093-3 +A1:2008 PN-EN 1093-4 A1:2010 PN-EN 1093-6+A1:2010 PN-EN 1093-7+A1:2010 PN-EN 1093-8+A1:2010 PN-EN 1093-9 A1:2010 PN-EN 1093-11 A1:2010 |
EN 626-1:1994+A1:2008 EN 626-2:1996+A1:2008 EN 1093-1:2008 EN 1093-2:2006+A1:2008 EN 1093-3:2006+A1:2008 EN 1093-4:1996+A1:2008 EN 1093-6:1998+A1:2008 EN 1093-7:1998+A1:2008 EN 1093-8:1998+A1:2008 EN 1093-9:1998+A1:2008 EN 1093-11:2001+A1:2008 |
The applied principles of emission control and their impact on safety are presented in Table 1.10.
Table 1.10. Reducing machine emissions and the impact of these measures on safety
|
Item |
Emission type |
Impact on safety |
Method of implementation |
|
1 |
Noise |
Reduction of work noise nuisance and the risk of injuries |
· enclosures; · screens fitted on machines; · silencers. |
|
2 |
Vibrations |
Reduction of work noise nuisance and the risk of injuries |
· vibration dampers placed between the source and the person exposed to vibration; · elastic suspensions; · seats with a shock absorbing suspension system. |
|
3 |
Harmful substances |
Reduction of work noise nuisance and the risk of diseases |
· machine enclosure; · local exhaust ventilation with filtration; · wetting with liquids; · air curtains; · operator booths. |
|
PN-EN ISO 13849-1:2008 PN-EN 60204-1:2010 |
EN ISO 13849-1:2008 EN 60204-1:2006+A1:2009 |
|
PN-EN ISO 12100:2012 PN-EN ISO 13849-1:2008 PN-EN ISO 13850:2012 |
EN ISO 12100:2010 EN ISO 13849-1:2008 EN ISO 13850:2008 |
Complementary protective measures are not inherently safe design solutions, engineering control measures (guards and/or protective devices) or information on the use. Their use results from both the operation of the machine in accordance with its intended purpose and from an anticipated improper use. The measures as those are shown in Table 1.11.
Table 1.11. Use of complementary protective measures and their effect on safety
|
Item |
Complementary protective measure |
Impact on safety |
Method of implementation |
|
1 |
Devices implementing the emergency stop function [13] |
Reducing the risk of injury |
· easy recognition, good visibility and easy accessibility of emergency stop device controls; · stopping, as soon as possible (without creating additional hazards), the process performed by the machine posing the hazard; · emergency stop device causing certain movements of engineering control measures fitted on the machine or making it possible to cause such movements (e.g. activation of the brake stopping the inertial movement of a hazardous element); · maintaining the effect of operation of a machine stop signal until the control element is reset (resetting should only make it possible to start up the machine and not restart it). |
|
2 |
Measures for disconnection and dissipation of energy |
Reducing the risk of injuries caused by entanglement, entrapment and enmeshment by the machine |
· escape routes and places of refuge in systems posing a hazard of operator entrapment; · devices for manual movement of certain elements, following an emergency stop; · equipment enabling reverse movement of some elements; · anchor points of equipment for climbing up and down; · means of communication to enable trapped persons calling for help. |
|
3 |
Measures for disconnection and dissipation of energy |
Reducing the risk of injuries caused by unintended machine startup |
· isolating (disconnecting, separating) the machine or certain parts of the machine from all power sources; · key lockable (or protected in another manner) of all disconnecting devices in the lockout position; · dispersing or, if this is not possible or practicable, stopping (absorbing) all stored energy which can be hazardous. |
|
4 |
Means for relocation of machines and heavy elements thereof |
Reducing the risk of injuries caused by compression, crushing and impact by a machine being moved or elements thereof |
· standardised lifting gear with loops, hooks, eyebolts or threaded holes for attaching the gear; · devices for automatically hooking a crane hook when it is not possible to attach the hook from the ground; · solutions for placing the forks in the right place for machines handled with forklift trucks; · devices for lifting and storage integrated into the machine; · devices enabling safe removal and insertion of replaceable parts during machine operation. |
|
5 |
Means for safe access to machines |
Reducing the risk of injuries (e.g. during falls from heights) occurring during operation and other tasks related to machine setting and/or maintenance [14–16] |
· if possible, ensuring actions performed from the ground level; · access walkways, stairs or other equipment providing safe access to perform the operations; · building pedestrian traffic areas of non-slip materials under operating conditions (as much as this is possible); · protecting pedestrian areas at a height with the use of appropriate railing (where necessary, install anchor points for personal protective equipment providing protection against falls from height); · ensuring safe means of access to large automated systems with the use of walkways and access paths, catwalks or junctions; · closures of openings opening in a safe direction, taking into account risks arising as a result of their unexpected opening or closing; · auxiliary means of access (e.g. steps, handles); · preventing (through appropriate design and location) the use of control devices as auxiliary means of access; · fitting levels for unloading machines for lifting loads and/or people with guards to prevent falls from height (in the event of stopping at a height where there is no catwalk). The movement of the carrier should prevent opening these guards. |
|
PN-EN ISO 12100:2012 |
EN ISO 12100:2010 |
|
PN-EN 60204-1:2010 PN-EN 61310-1:2010 PN EN 842+A1:2010 PN EN 981+A1:2010 |
EN 60204-1:2006+A1:2009 EN 61310-1:2008 EN 842:1996+A1:2008 EN 981:1996+A1:2008 |
|
PN-EN 61310-1:2010 PN-EN 61310-2:2010 PN-EN 61310-3:2010 |
EN 61310-1:2008 EN 61310-2:2008 EN 61310-3:2008 |
The users should be provided with information on how to use the machine as intended, in particular with regard to all types of work. It should include all the guidance required to ensure appropriate use of the machine to ensure safety. The user should be made aware of the residual risk and warned against it. Information on the use should apply to the necessary training, essential personal protective equipment and the use of additional guards and protective devices.
Table 1.12. Types of information and its location on the machine or in the documentation
|
Item |
Type of information |
Location of information |
Method of implementation of safety requirements during the machine design |
|
1 |
Verbal information |
In the accompanying documentation On the packaging |
· appropriate content of the accompanying documentation (in particular the user’s manual) acc. to PN-EN ISO 12100 |
|
2 |
Signals and warning devices |
On/in the machine Outside the machine |
· use of visual [17] and acoustic [18] signals to warn about an imminent event posing a hazard, such as a machine startup or excessive speed; · use of visual and acoustic signals to warn the operator before automatic activation of safeguards; · ensuring signals are emitted before a hazardous event occurs; · ensuring uniqueness of emitted signals; · ensuring clear perception of the emitted signals and distinguishing them (from any other signals in use); · providing clear identification of signals emitted by the operator or other persons; · allowing regular inspection of devices through their appropriate location and construction, as well as providing relevant information on their use; · taking into account the possibility of overloading the senses of sight and hearing during operation (resulting in an excess of visual and/or acoustic signals). |
|
3 |
Markings, symbols (pictograms) and warning notices |
On/in the machine
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· identification marking (name and address of the manufacturer, designation of the series or type, serial number – if applicable); · applied marking confirming compliance with applicable requirements (signs and manufacturer’s written information); · labelling related to safety during operation (maximum speed of rotating parts, maximum tool diameter, weight of the machine and/or detachable parts, maximum working load, the necessity to use personal protection equipment, guard adjustment data, information about inspection intervals); · ensuring that information placed directly on the machine is durable and legible throughout the expected life of the machine; · ensuring that labelling, symbols or warning notices are easy to understand and unambiguous; · prefering clear symbols (pictograms) for warning notices. |
Information on the use should include all reasonably anticipated uses of the machine, as well as the risks caused by the use of the machine other than described in the information, including a foreseeable improper use. Information should include all phases of machine life, i.e. shipment, assembly and installation, commissioning, operation (setting, learning/programming, process changing, service, cleaning, troubleshooting, and maintenance and repair), decommissioning, dismantling and scrapping (if necessary).
Types of information and its location are shown in Table 1.12.
The machine manufacturer shall prepare a risk assessment, which shall also include information on risk mitigation measures. The documentation shall include:
- information about the machine, such as technical data, limitations, the intended use;
- all adopted important design assumptions concerning the load, strength and safety factors;
- hazards, potentially hazardous situations and safety incidents taken into account in the risk assessment process;
- information used in the risk assessment;
- the data used and its sources (data and statistics on accidents, experience in building other similar machines);
- information about the uncertainty concerning the data used and its impact on the outcome of the risk assessment;
- risk reduction targets, to be achieved with the use of protective measures;
- a list of protective measures implemented to eliminate identified hazards or to reduce the risk;
- residual risk associated with the machine;
- risk assessment result;
- all other records made during the risk assessment;
- the establishment of standards or other technical specifications used in the selection of safeguards.
1. PN-EN ISO 12100:2012 Safety of machinery – General principles for design – Risk assessment and risk reduction
2. PN-EN ISO 13857:2010 Safety of machinery – Safety distances to prevent hazard zones being reached by upper and lower limbs
3. PN-EN ISO 11688-1:2010 Acoustics – Recommended practice for the design of low-noise machines and equipment – Part 1: Design
4. PN-EN ISO 10075-1:2002 Ergonomic principles related to mental workload – Part 1: General terms and definitions
5. PN-EN ISO 10075-2:2002 Ergonomic principles related to mental workload – Part 2: Design principles
6. PN-EN ISO 10075-3:2005 Ergonomic principles related to mental workload – Part 3: Principles and requirements concerning methods for measuring and assessing mental workload
7. PN-EN 614-1+A1:2009 Safety of machinery – Ergonomic design principles – Part 1: Terminology and general principles
8. PN-EN 13861:2012 Safety of machinery – Guidance for the application of ergonomics standards in the design of machinery
9. PN-EN 61310-1:2009 Safety of machinery – Indication, marking and actuation – Part 1: Requirements for visual, acoustic and tactile signals
10. PN-EN 60204-1:2010 Safety of machinery – Electrical equipment of machines – Part 1: General requirements
11. PN EN ISO 4413: 2011 Hydraulic fluid power – General rules and safety requirements
12. PN EN ISO 4414: 2011 Pneumatic fluid power – General rules and safety requirements for systems and their components
13. PN EN ISO 13850:2012 Safety of machinery – Emergency stop – Principles for design
14. PN-EN ISO 14122-1:2005+A1:2010 Safety of machinery – Permanent means of access to machinery – Part 1: Choice of fixed means of access between two levels
15. PN-EN ISO 14122-2:2005+A1:2010 Safety of machinery – Permanent means of access to machinery – Part 2: Working platforms and walkways
16. PN-EN ISO 14122-3:2005+A1:2010 Safety of machinery – Permanent means of access to machinery – Part 3: Stairways, stepladders and guard-rails
17. PN EN 842+A1: 2010 Safety of machinery – Visual danger signals – General requirements, design and testing
18. PN EN 981+A1: 2010 Safety of machinery – System of auditory and visual danger and information signals