Combined EHSRand PUWER

7/30/2019 Combined EHSRand PUWER

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COMBINED ASSESSMENT OF COMPLIANCE WITH THE MACHINERY

DIRECTIVE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS(as detailed in Annex 1 of the Machinery Directive 2006/42/EC) AND THE

PROVISION AND USE OF WORK EQUIPMENT REGULATIONS 1998 (PUWER)

MACHINE IDENTIFICATION & LIMITS

Manufacturer

Machine Description

Model / Type

Serial No

Is the machine CE marked?Yes No

Year ofmanufacture

NOTE - Machinery manufactured after 1st January 1995 must be CE marked

Sources of energy Mechanical Yes No kW

Electricity Yes No 415 volts (3 Phase, Neutral and Earth), 50Hz

Gas Yes No

Air Yes No 6 Bar dry air

Water Yes No

Steam Yes No

Hydraulics Yes No

Thermal

Max C Source -

Normal C

Min C Source -

Product

Pressure Bar

Temperature Max C Min C

Hazards

Machine maximum safecapabilities i.e. machinedesign criteria

Maximum Safe Speed units of measure

Note - Speed does not mean operational speed. It means the absolutemaximum speed at which the machine can be safely operated.

Maximum weight the machine is capable of handling kg

Size limitations of machine

Installed Location andEnvironmental Conditions

DECLARATION OF COMPLIANCE

Tick applicable box Assessed By Date of Assessment

This machine has been assessed as being fully compliant with the combined requirements ofboth the Essential Health and Safety Requirements as detailed in Annex 1 of the MachineryDirective 2006/42/EC and the Provision and Use of Work Equipment Regulations 1998(PUWER)


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COMBINED ASSESSMENT OF COMPLIANCE WITH THE MACHINERYDIRECTIVE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS

(as detailed in Annex 1 of the Machinery Directive 2006/42/EC) ANDTHE PROVISION AND USE OF WORK EQUIPMENT REGULATIONS 1998 (PUWER)

This machine has been assessed as being not compliant with the combined requirements ofboth the Essential Health and Safety Requirements as detailed in Annex 1 of the Machinery

Directive 2006/42/EC and the Provision and Use of Work Equipment Regulations 1998(PUWER). Reasons for the non compliance are given in the Notes section at the end of theassessment.


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Page 3 of 36

COMBINED ASSESSMENT OF COMPLIANCE WITH THE MACHINERYDIRECTIVE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS

(as detailed in Annex 1 of the Machinery Directive 2006/42/EC) ANDTHE PROVISION AND USE OF WORK EQUIPMENT REGULATIONS 1998 (PUWER)

Document InformationCOMBINED ASSESSMENT OF COMPLIANCE WITH THE MACHINERY

DIRECTIVE ESSENTIAL HEALTH AND SAFETY REQUIREMENTS(as detailed in Annex 1 of the Machinery Directive 2006/42/EC) AND

THE PROVISION AND USE OF WORK EQUIPMENT REGULATIONS 1998 (PUWER)

Prepared By:

Graham Cooke, Unilever PLC, Port Sunlight

Revision Record

Revision: Date: Summary:

1.0 24/05/2010 First Issue.

1.1 04/04/2010 General update

Document Control

This is a generic document for use in assessing the compliance of machinery with the both theMachinery Directive Essential Health and Safety Requirements and the Provision and Use of WorkEquipment Regulations 1998 (PUWER) and as such should not be modified to apply to individual sitesor individual items of machinery.

The document is freely available for use within Unilever, however in order to maintain it as a controlleddocument, it will only be distributed as either a Word protected document or in Acrobat PDF format.The master document will be held by Graham Cooke

Associated References

This document refers to the following Directives and Standards

Machinery Directive Directive 2006/42/EC of the European Parliament and Council of 17th May 2006

BSEN 60204-1:2006 Safety of machinery - Electrical equipment of machines.Part 1 General requirements

PUWER The Provision and Use of Work Equipment Regulations 1998


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IMPORTANT

This document is an assessment of compliance with the Machinery Directive Essential Health andSafety requirements (as detailed in annex 1 of the machinery directive 2006/42/EC) and theProvision and Use of Work Equipment Regulations 1998 (PUWER) and is therefore only applicableto machines and equipment which is already CE marked.

If equipment is not already CE marked then a full CE assessment must be

undertaken

NOTES ON UNDERTAKING THIS ASSESSMENT

This assessment of compliance is based upon the published Essential Health and Safety Requirements of Annex1 of the Machinery Directive 2006/42/EC (which came into force on 29th December 2009) and the Provision andUse of Work Equipment Regulations 1998 (as amended).

The reason for this combined assessment document is based upon the requirements of PUWER Regulation 10.This regulation relates to Conformity with Community Requirements.In order to comply with this Regulation an assessment of compliance with the Essential Health and SafetyRequirements contained within Annex 1 of the Machinery Directive 2006/42/EC must be undertaken.As there is great similarity and duplication between the requirements of the Essential Health and SafetyRequirements and the requirements of the PUWER Regulations, it seemed beneficial to combine both documentsinto one assessment of compliance.

The heading of each section identifies the source, either the appropriate section of the Essential Health andSafety Requirements or the Regulation number of the Provision and Use of Work Equipment Regulations.Each section contains some explanatory text, followed by a number of questions which act as a prompt todetermine whether the machine under assessment meets the requirements of that section. All questions arephrased such that a satisfactory assessment should have a response of either yes or not applicable.If any question prompts the answer no then additional notes or the completion of a risk assessment must beadded to the end of the assessment giving further information and the reasons for such a response.

It is important to note that the Essential Health and Safety Requirements of the Machinery Directive aremandatory. However, taking into account the state of the art, it may not be possible to meet the objectives set bythem. In that event, the machinery must, as far as possible, be designed and constructed with the purpose ofapproaching these objectives.

WHEN TO UNDERTAKE THIS ASSESSMENT

It is a requirement of the Provision and Use of Work Equipment Regulations 1998 (known as the PUWERRegulations) that all equipment is inspected

following installation and before being put into service for the first time

following assembly at a new site or in a new location

following major modification, for example if changes are made to -

Any of the safety measures employed e.g. guarding, safety interlocks etc.

The machine function e.g. the machine now fills cartons rather than bottles, fills acid rather than

water, i.e. a whole new set of risks are being introduced.

the machine performance e.g. increase in speed outside of the safe operating limits given by theoriginal machine manufacturer

any change where the effects are not immediately determinable but may have an influence on safety

e.g. change of a control system from relay control to PLC control

periodically at suitable intervals

After work equipment has been exposed to any conditions or exceptional circumstance which has the

potential to jeopardise the safety of work equipment.


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GENERAL REQUIREMENTS

Definitions EHSR 1.1.1

(a) hazard means a potential source of injury or damage to health;

(b) danger zone means any zone within and/or around machinery in which a person is subject to a risk to hishealth or safety;

(c) exposed person means any person wholly or partially in a danger zone;

(d) operator means the person or persons installing, operating, adjusting, maintaining, cleaning, repairing ormoving machinery;

(e) risk means a combination of the probability and the degree of an injury or damage to health that can arisein a hazardous situation;

(f) guard means a part of the machinery used specifically to provide protection by means of a physicalbarrier;

(g) protective device means a device (other than a guard) which reduces the risk, either alone or in conjunc-tion with a guard;

(h) intended use means the use of machinery in accordance with the information provided in the instructionsfor use;

(i) Reasonably foreseeable misuse means the use of machinery in a way not intended in the instructions foruse, but which may result from readily predictable human behaviour.

Conformity with Community Requirements PUWER Regulation 10

Where equipment was brought into service before 31st December 1992, it is not required to be CE marked.

Where equipment was brought into service after 31st December 1992 then such equipment shall be CEmarked to indicate that the equipment manufacturer is claiming compliance with the Machinery DirectiveEssential Health and Safety Requirements.

Because this assessment combines with the requirements of the Provision and Use of Work EquipmentRegulations (PUWER) with the requirements of the Machinery Directive Essential Health and Safety

Requirements then compliance with regulation 10 is assumed.

Has the machine already been CE marked?(if NO then do not continue with this assessment a full CE certification is required)

Yes No

Citation and commencement PUWER Regulation 1

The Provision and Use of Work Equipment Regulations apply to all work equipment brought into use after 5thDec 1998.

Even if the equipment was brought into service before this date, it will be deemed to be new equipment andtherefore subject to these Regulations if any of the following types of modifications have been made -

any of the safety measures employed e.g. guarding, safety interlocks etc.

the machine function e.g. the machine now fills cartons rather than bottles, fills acid rather than water,i.e. a whole new set of risks are being introduced.

the machine performance e.g. increase in speed outside of the original safe operating limits given bythe original machine manufacturer

any change where the effects are not immediately determinable but may have an influence on safety e.g.change of a control system from relay control to PLC control

Based upon the above criteria, do the requirements of the Provision and Use ofWork Equipment Regulations apply to this equipment?

Yes No


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Interpretation PUWER Regulation 2

Work equipment means any machinery, appliance, apparatus, tool or installation for use at work.

Is the equipment being assessed interpreted as being work equipment?Yes No

Application PUWER Regulation 3

This assessment for compliance with the Provision and Use of Work Equipment Regulations is only applicablefor fixed equipment installations because only regulations 1 24 have been considered.. If the equipment ismobile, then additional regulations 25 30 must also be considered.

Is the equipment designed and intended for fixed equipment installations only?If Yes then only regulations 1 24 need to be considered.If No then regulations 25 30 must also be considered.

Yes Regulations 25-30also included

Principles of Safety Integration EHSR 1.1.2

a) Machinery must be designed and constructed so that it is fit for its function and can be operated, adjustedand maintained without putting persons at risk when these operations are carried out under the conditionsforeseen but also taking into account any reasonably foreseeable misuse thereof.The aim of measures taken must be to eliminate any risk throughout the foreseeable lifetime of themachinery including the phases of transport, assembly, installation, commissioning, use, de-commissioning,dismantling, and disposal.

b) In selecting the most appropriate methods, the manufacturer or his authorised representative must apply thefollowing principles, in the order given: Eliminate or reduce risks as far as possible (inherently safe machinery design and construction).

Take the necessary protective measures in relation to risks that cannot be eliminated.

Inform users of the residual risks due to any shortcomings of the protective measures adopted, indicatewhether any particular training is required and specify any need to provide personal protective equipment.

c) When designing and constructing machinery and when drafting the instructions, the manufacturer or hisauthorised representative must envisage not only the intended use of the machinery but also any reasonablyforeseeable misuse thereof.The machinery must be designed and constructed in such a way as to prevent abnormal use if such usewould engender a risk. Where appropriate, the instructions must draw the users attention to ways, whichexperience has shown might occur, in which the machinery should not be used

d) Machinery must be designed and constructed to take account of the constraints to which the operator issubject as a result of the necessary or foreseeable use of personal protective equipment

e) Machinery must be supplied with all the special equipment and accessories essential to enable it to beadjusted, maintained and used safely.

Is the machine fit for its function and can it be operated, adjusted and maintained

(when undertaken as intended by the manufacturer) without putting persons at risk ?

Yes No See notes

Has the person responsible for designing or constructing the machine undertaken amachinery risk assessment and have all the hazards identified by such anassessment been addressed, by either

elimination or reduction of the risks by design and/or method of construction Taking the necessary protective measures in relation to risks that cannot be

eliminated. Informing the users of any residual risks due to any shortcomings of the

protective measures adopted, and indicating whether any particular training orpersonal protective equipment is required.

Be aware that if the machine has been modified since the risk assessment wasundertaken, hazards may have been introduced by inadequate consideration of the

risks when the modification was being made. Therefore, depending upon the age ofthe machine being assessed and the reasons for undertaking this assessment ofcompliance with the Machinery Directive, it may be advisable to also undertake anew risk assessment to ensure that any hazards which may have not beenconsidered previously are now identified and addressed.

Yes No See notes


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Has the machine been designed and constructed in such a way as to preventabnormal use if such use would engender a risk and where appropriate, have theinstructions drawn the users attention to ways, which experience has shown mightoccur, in which the machinery should not be used ?

Yes No See notes

Has the machine design taken into account operator constraints due to the use ofpersonal protection equipment (such as footwear, gloves, ear defenders, face masks,spectacles etc)?

Yes No See notes

Has all necessary special equipment and accessory items been supplied to allowuse, adjustment and maintenance without risk?

Yes No See notes


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Suitability of Work Equipment PUWER Regulation 4

Assessment of the initial integrity of the equipment

Equipment must be suitable, by design, construction or adaptation, for the actual work it is provided to do. Thismeans in practice that when you provide work equipment you should ensure that it is suitable for the work to beundertaken and that it is used in accordance with the manufacturer's specifications and instructions. If workequipment is adapted it must still be suitable for its intended purpose.

Is the equipment suitable for the work to be undertaken?Yes Risk Assessment

carried out

Assessment of the installed location

This requires you to assess the location in which the work equipment is to be used and to take account of anyrisks that may arise from the particular circumstances. Such factors can invalidate the use of work equipment in aparticular place. For example, electrically powered equipment is not suitable for use in wet or flammableatmospheres unless it is designed for this purpose.

You should ensure that work equipment is installed, located and used in such a way as to reduce risks to usersof work equipment and for other workers, such as ensuring that there is sufficient space between the movingparts of work equipment and fixed or moving parts in its environment

When determining the suitability of work equipment, you should ensure that where appropriate -(1) all forms of energy used or produced; and(2) all substances used or produced can be supplied and/or removed in a safe manner

Is the equipment suitable for the installed location?Yes Risk Assessment

carried out

Assessment of the purpose for which the equipment will be used.

This requirement concerns each particular process for which the work equipment is to be used and theconditions under which it will be used. You must ensure that the equipment is suitable for the process andconditions of use. Examples include -

a circular saw is generally not suitable for cutting a rebate whereas a spindle molding machine would be

suitable because it can be guarded to a high standard; knives with unprotected blades are often used for cutting operations where scissors or other cutting tools

could be used, reducing both the probability and severity of injury

Is the equipment suitable for its intended purpose?Yes Risk Assessment

carried out

Assessment of ergonomic risks

Ergonomic design takes account of the size and shape of the human body and should ensure that the design iscompatible with human dimensions. Operating positions, working heights, reach distances; etc can be adapted toaccommodate the intended operator. Operation of the equipment should not place undue strain on the user.Operators should not be expected to exert undue force or stretch or reach beyond their normal strength orphysical reach limitations to carry out tasks.

Have ergonomic risks been considered and either designed out or else are appropriatecontrol measures in place?

Yes Risk Assessment

carried out


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Inspection PUWER Regulation 6

When should equipment be inspected -

(1) Every employer shall ensure that, where the safety of work equipment depends on the installationconditions, it is inspected -(a) after installation and before being put into service for the first time; or(b) After assembly at a new site or in a new location, to ensure that it has been installed correctly and is

safe to operate.

(2) Every employer shall ensure that work equipment exposed to conditions causing deterioration which is liableto result in dangerous situations is inspected -(a) at suitable intervals; and(b) each time that exceptional circumstances which are liable to jeopardise the safety of the work

equipment have occurred,(c) To ensure that health and safety conditions are maintained and that any deterioration can be detected

and remedied in good time.

Purpose of an inspection -

The purpose of an inspection is to identify whether the equipment can be operated, adjusted and maintainedsafely and that any deterioration (for example defect, damage, wear) can be detected and remedied before itresults in unacceptable risks.

Who should undertake the inspection -

The person who carries out the inspection and functional tests shall be able to demonstrate competency to doso by means of having the necessary knowledge and experience to -

(a) enable them to know what to look at (know the key components)(b) know what to look for (fault-finding) and(c) Know what to do (reporting faults, making a record, who to report to).

The necessary level of competence will vary according to the type of equipment and where and how it isused.

Either

Equipment is regularly inspected for deterioration (for example defect, damage, wear)

in relation to safety and safety related devices and control systems

This is an initial inspection of new equipment

Yes Risk Assessment

carried out

Can the equipment can be operated, adjusted and maintained safely?Yes Risk Assessment

carried out

Testing

As part of an inspection, a functional test should be undertaken to check that the safety-related parts, forexample interlocks, protection devices, controls, etc are working as they should be and that the workequipment and relevant parts are structurally sound.

Has a functional test of all safety related devices been undertaken?Yes Risk Assessment

carried out

Are electrical safety tests performed on all new items of fixed equipment and on allportable equipment and machinery?

Yes Risk Assessment

carried out


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Materials and products EHSR 1.1.3

The materials used to construct machinery or products used or created during its use must not endanger personssafety or health. In particular, where fluids are used, machinery must be designed and constructed to prevent risksdue to filling, use, recovery or draining

Is the machine constructed entirely of non-hazardous materials?Yes No See notes

Are exposed persons protected from any hazards due to materials or products used orcreated by the machine?This includes not only good production but also any waste, spillage, rejected materialsetc

Yes No See notes

Where fluids are used on the machine, has the machine been designed to allow forsafe filling, use, recovery and draining?

Yes No N/A See notes

LightingEHSR 1.1.4PUWER Regulation 21

Machinery must be supplied with integral lighting suitable for the operations concerned where the absence thereofis likely to cause a risk despite ambient lighting of normal intensity

Machinery must be designed and constructed so that there is no area of shadow likely to cause nuisance, thatthere is no irritating dazzle and that there are no dangerous stroboscopic effects on moving parts due to thelighting.

Internal parts requiring frequent inspection and adjustment, and maintenance areas must be provided withappropriate lighting

Is the level and type of lighting suitable for the safe operation, inspection andmaintenance of the machinery?

Yes No See notes

Design of machinery to facilitate its handling EHSR 1.1.5

Machinery, or each component part thereof, must- be capable of being handled and transported safely- be packaged or designed so that it can be stored safely and without damage.

During the transportation of the machinery and/or its component parts, there must be no possibility of suddenmovements or of hazards due to instability as long as the machinery and/or its component parts are handled inaccordance with the instructions.

Where the weight, size or shape of machinery or its various component parts prevents them from being moved byhand, the machinery or each component part must either -

- be fitted with attachments for lifting gear, or- be designed so that it can be fitted with such attachments, or- be shaped in such a way that standard lifting gear can easily be attached

Where machinery or one of its component parts is to be moved by hand, it must either -:- be easily moveable, or- be equipped for picking up and moving safely.

Special arrangements must be made for the handling of tools and/or machinery parts which, even if lightweight,could be hazardous.

Is the machinery, and each component part thereof, capable of being handled andtransported safely? Pay particular attention to interchangeable parts, changeoverparts etc.

Yes No See notes


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Ergonomics EHSR 1.1.6

Under the intended conditions of use, the discomfort, fatigue and physical and psychological stress faced by theoperator must be reduced to the minimum possible, taking into account ergonomic principles such as:

- Allowing for the variability of the operators physical dimensions, strength and stamina.- providing enough space for movements of the parts of the operators body- Avoiding a machine-determined work rate.

- Avoiding monitoring that requires lengthy concentration.- adapting the man/machinery interface to the foreseeable characteristics of the operators

Has the machine design taken into account ergonomic principles to minimisediscomfort, fatigue, physical and psychological stress faced by the operator ?

Yes No See notes

Operating Positions EHSR 1.1.7

The operating position must be designed and constructed in such a way as to avoid any risk due to exhaustgases and/or lack of oxygen.

If the machinery is intended to be used in a hazardous environment presenting risks to the health and safety ofthe operator or if the machinery itself gives rise to a hazardous environment, adequate means must be provided

to ensure that the operator has good working conditions and is protected against any foreseeable hazards.Where appropriate, the operating position must be fitted with an adequate cabin designed, constructed and/orequipped to fulfill the above requirements. The exit must allow rapid evacuation. Moreover, when applicable, anemergency exit must be provided in a direction which is different from the usual exit.

Is the normal machinery operating position located and/or constructed in such a wayas to avoid any risk due to exhaust, corrosive, obnoxious or harmful gases and/or lackof oxygen?

Yes No See notes

Seating EHSR 1.1.8

Where appropriate and where the working conditions so permit, work stations constituting an integral part of themachinery must be designed for the installation of seats

If the operator is intended to sit during operation and the operating position is an integral part of the machinery,the seat must be provided with the machinery

The operators seat must enable him to maintain a stable position. Furthermore, the seat and its distance from thecontrol devices must be capable of being adapted to the operatorIf the machinery is subject to vibrations, the seat must be designed and constructed in such a way as to reduce thevibrations transmitted to the operator to the lowest level that is reasonably possible. The seat mountings mustwithstand all stresses to which they can be subjected. Where there is no floor beneath the feet of the operator,footrests covered with a slip-resistant material must be provided.

Where appropriate and where the working conditions permit, has seating or theprovision for seating been allowed for?



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CONTROLS

Safety and reliability of control systemsEHSR 1.2.1PUWER Regulation 18

Control systems must be designed and constructed in such a way as to prevent hazardous situations fromarising. Above all, they must be designed and constructed in such a way that:

- They can withstand the intended operating stresses and external influences.- A fault in the hardware or the software of the control system does not lead to hazardous situations.- Errors in the control system logic do not lead to hazardous situations.- Reasonably foreseeable human error during operation does not lead to hazardous situations.

Particular attention must be given to the following points:- The machinery must not start unexpectedly.- The parameters of the machinery must not change in an uncontrolled way where such change may lead

to hazardous situations.- The machinery must not be prevented from stopping if the stop command has already been given.- No moving part of the machinery or piece held by the machinery must fall or be ejected.- Automatic or manual stopping of the moving parts, whatever they may be, must be unimpeded.- The protective devices must remain fully effective or give a stop command.- The safety-related parts of the control system must apply in a coherent way to the whole of an assembly

of machinery and/or partly completed machinery.

For cable-less control, an automatic stop must be activated when correct control signals are not received,including loss of communication.

Will the control system withstand the rigors of normal use ?Yes No See notes

In the event of a fault in the hardware or the software of the control system, will themachine still be capable of stopping safely?

Yes No See notes

In the event of errors in the control system logic, will the machine still be capable ofstopping safely?

Yes No See notes

Will all reasonably foreseeable human errors which may occur during normaloperation be prevented from leading to a hazardous situation?

Yes No See notes

Is the machine control system either hard wired, or

cable-less, in which case is there provision for an automatic stop beingactivated when correct control signals are not received, including loss ofcommunication ?

Yes No See notes

If a hydraulic control system is utilised, is all equipment in good conditionYes No N/A See notes

If a pneumatic control system is utilised, is all equipment in good conditionYes No N/A See notes


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Control devicesEHSR 1.2.2PUWER Regulation 17

Control devices must be:- Clearly visible and identifiable, using pictograms where appropriate.- Positioned in such a way as to be safely operated without hesitation or loss of time and without ambiguity.- Designed in such a way that the movement of the control device is consistent with its effect.

- Located outside the danger zones, except where necessary for certain control devices such as anemergency stop or a teach pendant.

- Positioned in such a way that their operation cannot cause additional risk.- Designed or protected in such a way that the desired effect, where a hazard is involved, can only be

achieved by a deliberate action.- Made in such a way as to withstand foreseeable forces, particular attention must be paid to emergency

stop devices liable to be subjected to considerable forces.

Where a control device is designed and constructed to perform several different actions. Namely where there isno one-to-one correspondence, the action to be performed must be clearly displayed and subject toconfirmation, where necessary.

Control devices must be so arranged that their layout, travel and resistance to operation are compatible with theaction to be performed, taking account of ergonomic principles.

Machinery must be fitted with indicators as required for safe operation. The operator must be able to read themfrom the control position.

From each control position, the operator must be able to ensure that no-one is in the danger zones, or thecontrol system must be designed and constructed in such a way that starting is prevented while someone is inthe danger zone. If neither of these possibilities is applicable, before the machinery starts, an acoustic and/orvisual warning signal must be given. The exposed persons must have time to leave the danger zone or preventthe machinery starting up.

If necessary, means must be provided to ensure that the machinery can be controlled only from control positionslocated in one or more predetermined zones or locations.

Where there is more than one control position, the control system must be designed in such a way that the useof one of them precludes the use of the others, except for stop controls and emergency stops.When machinery has two or more operating positions, each position must be provided with all the required control

devices without the operators hindering or putting each other into a hazardous situation.

Are the control devices clearly visible & clearly identified with their functions?Yes No See notes

Are the control devices designed (i.e. positioned, labelled etc) in such a manner thatits use or movement is consistent with its effect?

Yes No See notes

Are the control devices located outside the danger zones, except where necessary forcertain control functions such as an emergency stop or a teach pendant ?

Yes No See notes

Are the control devices positioned in such a way that their operation cannot causeadditional risk?

Yes No See notes

Are the control devices designed to avoid unintentional operation? Yes No See notes

Will the control devices withstand the rigors of normal use?Yes No See notes

Has the machine operator a clear observation to be able to ensure that no-one is inthe danger zone before starting the machine, or if the operator does not have clearobservation, has the control system been designed and constructed in such a way thatstarting is prevented while there is a possibility of someone being in the danger zone?

Yes No See notes

If the machine operatordoes nothave clear observation of the whole machine in orderto be able to ensure that no-one is in the danger zone before starting the machine, thenis there a delayed start and an appropriate visual or audible warning system



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StartingEHSR 1.2.3PUWER Regulation 14

It must be possible to start machinery only by voluntary actuation of a control device provided for the purpose.

The same requirement applies:- When restarting the machinery after a stoppage, whatever the cause.- When effecting a significant change in the operating conditions.

However, the restarting of the machinery or a change in operating conditions may be effected by voluntaryactuation of a device other than the control device provided for the purpose, on condition that this does not leadto a hazardous situation.

For machinery functioning in automatic mode, the starting of the machinery, restarting after a stoppage or achange in operating conditions may be possible without intervention, provided this does not lead to a hazardoussituation.Where machinery has several starting control devices and the operators can therefore put each other in danger,additional devices must be fitted to rule out such risks. If safety requires that starting and/or stopping must beperformed in a specific sequence, there must be devices which ensure that these operations are performed inthe correct order.

Can the machine only be started by voluntary actuation of a control device provided

for the purpose either - from one location only, or

from one of several locations, in which case can the machine be startedwithout operators putting each other at risk ?

Where safety requires that starting and/or stopping be performed in a specificsequence, are there devices which ensure that these operations are performed in thecorrect order?

Yes No See notes

After a stop, is the machine prevented from restarting automatically?Yes No See notes


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StoppingEHSR 1.2.4PUWER Regulation 15PUWER Regulation 16

1.2.4.1 Normal stop

Machinery must be fitted with a control device whereby the machinery can be brought safely to a complete stop.

Each workstation must be fitted with a control device to stop some or all of the functions of the machinery,depending on the existing hazards, so that the machinery is rendered safe.

The machinerys stop control must have priority over the start controls.

Once the machinery or its hazardous functions have stopped, the energy supply to the actuators concernedmust be cut off.

It is acknowledged that it is not always desirable to bring all items of work equipment immediately to a completestop if this could result in other risks The stop control does not have to be instantaneous in its action and canbring the equipment to rest in sequence or at the end of an operating cycle if this is required for safety. Theactual process of bringing the equipment to a safe condition shall be determined by risk assessment.

1.2.4.2 Operational stop

Where, for operational reasons, a stop control that does not cut off the energy supply to the actuators is

required, the stop condition must be monitored and maintained.

1.2.4.3 Emergency stop

Machinery must be fitted with one or more emergency stop devices to enable actual or impending danger to beaverted.

The following exceptions apply:- Machinery in which an emergency stop device would not lessen the risk, either because it would not

reduce the stopping time or because it would not enable the special measures required to deal with therisk to be taken.

- Portable hand-held and/or hand-guided machinery.

The device must:- Have clearly identifiable, clearly visible and quickly accessible control devices.

- Stop the hazardous process as quickly as possible, without creating additional risks.- Where necessary, trigger or permit the triggering of certain safeguard movements.

Once active operation of the emergency stop device has ceased following a stop command. That commandmust be sustained by engagement of the emergency stop device until that engagement is specifically over-ridden; it must not be possible to engage the device without triggering a stop command; it must be possible todisengage the device only by an appropriate operation. And disengaging the device must not restart themachinery but only permit restarting.

The emergency stop function must be available and operational at all times, regardless of the operating mode.Emergency stop devices must be a back-up to other safeguarding measures and not a substitute for them.

1.2.4.4 Assembly of machinery

In the case of machinery or parts of machinery designed to work together, the machinery must be designed andconstructed in such a way that the stop controls, including the emergency stop devices, can stop not only themachinery itself but also all related equipment, if its continued operation may be dangerous.

Is each workstation of the machine fitted with a control device provided for thepurpose of bringing the machine to a complete stop in a safe manner?

Yes No See notes

Once the machinery or its hazardous functions have stopped is the energy supply tothe actuators concerned either

cut off, or

Where, for operational reasons, a stop control does not cut off the energysupply, is the stop condition monitored and maintained?

Yes No See notes

Is the machine fitted with emergency stops and are they operational?Yes No See notes

Are the emergency stops located at appropriate locations i.e. at every location wherean operator would reasonably be expected to be positioned?

Yes No See notes


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Are emergency stops devices of the correct type?Estop buttons are latching, manually reset and coloured red on a yellow

backgroundIsolators which also perform an emergency stop function are coloured red/yellow

(Note for information it is recommended in BSEN 60204-1:2006 Safety of Machinery Electrical Equipment of Machines section 5.3.3 that isolators which performs localisolation only and do not perform an estop function should be coloured black/grey and

not red/yellow)

Yes No See notes

Have all sub-assemblies been integrated correctly and safely into the main machinesafety control circuit?

Yes No See notes

Has the machine been designed so that the emergency stop function is also capable ofstopping equipment upstream and downstream if its continued operation can cause ahazardous situation?

Yes No See notes

Is all stored energy removed where necessary (except where dissipating stored energywould create additional hazards)?

Yes No See notes

Selection of control or operating modesEHSR 1.2.5

PUWER Regulation 14

The control or operating mode selected must override all other control or operating modes, with the exception ofthe emergency stop.

If machinery has been designed and constructed to allow its use in several control or operating modes requiringdifferent protective measures and/or work procedures, it must be fitted with a mode selector which can belocked in each position. Each position of the selector must be clearly identifiable and must correspond to asingle operating or control mode.

The selector may be replaced by another selection method which restricts the use of certain functions of themachinery to certain categories of operator.

If, for certain operations, the machinery must be able to operate with a guard displaced or removed and/or aprotective device disabled, the control or operating mode selector must simultaneously:

- Disable all other control or operating modes.- Permit operation of hazardous functions only by control devices requiring sustained action.- Permit the operation of hazardous functions only in reduced risk conditions while preventing hazards from

linked sequences.- Prevent any operation of hazardous functions by voluntary or involuntary action on the machines

sensors.

If these four conditions cannot be fulfilled simultaneously, the control or operating mode selector must activateother protective measures designed and constructed to ensure a safe intervention zone.In addition, the operator must be able to control operation of the parts he is working on from the adjustmentpoint.

Does the mode selector override all other control signals with the exception of theemergency stop?


If machinery has been designed and constructed to allow its use in several control oroperating modes requiring different protective measures and/or work procedures, hasa mode selector which can be locked in each position been fitted?


If operation of the mode selector affects safety circuits has the control beenimplemented safely?


If, for certain operations, the machinery must be able to operate with any of the safetyor protection device disabled, does the control or operating mode selectorsimultaneously

Disable all other control or operating modes.

Permit operation of hazardous functions only by control devices requiring

sustained action.

Permit the operation of hazardous functions only in reduced risk conditions

while preventing hazards from linked sequences?



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Failure of power supplyEHSR 1.2.6PUWER Regulation 18

The interruption, the re-establishment after an interruption or the fluctuation in whatever manner of the powersupply to the machinery must not lead to dangerous situationsParticular attention must be given to the following points

- The machinery must not start unexpectedly.- The parameters of the machinery must not change in an uncontrolled way when such change can lead to

hazardous situations.- The machinery must not be prevented from stopping if the command has already been given.- No moving part of the machinery or piece held by the machinery must fall or be ejected.- Automatic or manual stopping of the moving parts, whatever they may be, must be unimpeded.- The protective devices must remain fully effective or give a stop command.

In the event of a power failure, will the machine stop safely?Yes No See notes

When power is reinstated, is the machine prevented from starting unexpectedly?Yes No See notes

Following power failure / power restoration, are uncontrolled changes in machineparameters prevented from occurring, especially where such changes could lead to a

hazardous situation being created?

Yes No See notes

In the event of a power failure, will moving parts or pieces held by the machinery beprevented from either falling or being ejected?

Yes No See notes

In the event of a power failure, do either - the protective devices remain fully effective or

Is a stop command given ?

Yes No See notes


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PROTECTION AGAINST MECHANICAL HAZARDS

Risk of loss of stabilityEHSR 1.3.1PUWER Regulation 20

Machinery and its components and fittings must be stable enough to avoid overturning, falling or uncontrolledmovements during transportation, assembly, dismantling and any other action involving the machinery.

If the shape of the machinery itself or its intended installation does not offer sufficient stability, appropriatemeans of anchorage must be incorporated and indicated in the instructions.

Is the machine designed and constructed so that it is stable enough, under foreseenoperating conditions, for use without risk of overturning, falling or unexpectedmovement?

Yes No See notes

Risk of break-up during operationEHSR 1.3.2PUWER Regulation 12PUWER Regulation 20

The various parts of machinery and their linkages must be able to withstand the stresses to which they aresubject when used.

The durability of the materials used must be adequate for the nature of the working environment foreseen by themanufacturer or his authorised representative, in particular as regards the phenomena of fatigue, ageing,corrosion and abrasion.

The instructions must indicate the type and frequency of inspections and maintenance required for safetyreasons. They must, where appropriate, indicate the parts subject to wear and the criteria for replacement.

Where a risk of rupture or disintegration remains despite the measures taken, the parts concerned must bemounted, positioned and/or guarded in such a way that any fragments will be contained, preventing hazardoussituations.

Both rigid and flexible pipes carrying fluids, particularly those under high pressure, must be able to withstand theforeseen internal and external stresses and must be firmly attached and/or protected to ensure that no risk isposed by a rupture.

Where the material to be processed is fed to the tool automatically, the following conditions must be fulfilled toavoid risks to persons

- When the work piece comes into contact with the tool, the latter must have attained its normal workingcondition.

- When the tool starts and/or stops (intentionally or accidentally), the feed movement and the tool movementmust be coordinated.

Is the machine strong enough to withstand normal operating stresses?Yes No See notes

Risks due to failing or ejected objectsEHSR 1.3.3PUWER Regulation 12

Precautions must be taken to prevent risks from falling or ejected objects.

Have precautions been taken to prevent risks from falling or ejected objects?Yes No See notes

Risks due to surfaces, edges or angles EHSR 1.3.4

Insofar as their purpose allows, accessible parts of the machinery must have no sharp edges, no sharp anglesand no rough surfaces likely to cause injury.

Have rough surfaces and sharp edges and angles likely to cause injury been removed?Yes No See notes


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Risks related to combined machinery EHSR 1.3.5

Where the machinery is intended to carry out several different operations with manual removal of the piecebetween each operation (combined machinery), it must be designed and constructed in such a way as to enableeach element to be used separately without the other elements constituting a risk for exposed persons.

For this purpose, it must be possible to start and stop separately any elements that are not protected.

Can each element of a combined machinery installation be operated independentlywithout creating a hazard?

Note do not confuse the terms combined machinery with complex assemblycombined machinery is where the machinery is intended to carry out several differentoperations with manual removal of the piece between each operation.complex assembly is where an assembly of individual machines are linked togetherto form an integral whole, for example a complete production line.


Risks related to variations in operating conditions EHSR 1.3.6

Where the machinery performs operations under different conditions of use, it must be designed and constructedin such a way that selection and adjustment of these conditions can be carried out safely and reliably.

Is the machine designed in such a way that selection and adjustment to performdifferent operations can be carried out safely?

Yes No See notes

Risks related to moving parts EHSR 1.3.7PUWER Regulation 11

The moving parts of machinery must be designed and constructed in such a way as to prevent risks of contactwhich could lead to accidents or must, where risks persist, be fitted with guards or protective devices.

All necessary steps must be taken to prevent accidental blockage of moving parts involved in the work. In caseswhere, despite the precautions taken, a blockage is likely to occur, the necessary specific protective devices andtools must, when appropriate, be provided to enable the equipment to be safely unblocked.

The instructions and, where possible, a sign on the machinery shall identify these specific protective devices andhow they are to be used.

Have guards and other protective devices been designed and constructed so as toprevent risks of contact with any moving parts of machinery?

Yes No See notes

Can blockages of the moving parts be cleared safely without putting persons at risk?

Consider the possible actions of a machine operator who may see a potentialblockage before it actually happens and try to take impulsive corrective action in orderto prevent the blockage from stopping the production process. It must not be possiblefor the operator to put either himself or others at risk by taking impulsive action.

Yes No See notes


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Choice of protection against risks related to moving parts EHSR 1.3.8PUWER Regulation 11

Guards or protective devices designed to protect against risks arising from moving parts must be selected onthe basis of the type of risk. The following guidelines must be used to help to make the choice.

1.3.8.1 Moving transmission parts

Guards designed to protect persons against the hazards generated by moving transmission parts must be either- Fixed guards as referred to in section 1.4.2.1. or- Interlocking movable guards as referred to in section 1.4.2.2.

1.3.8.2 Moving parts involved in the processGuards or protective devices designed to protect persons against the hazards generated by moving partsinvolved in the process must be either -:

- Fixed guards as referred to in section 1.4.2.1. or- Interlocking movable guards as referred to in section 1.4.2.2. or- Protective devices as referred to in section 1.4.3. or- A combination of the above.

However, when certain moving parts directly involved in the process cannot be made completely inaccessibleduring operation owing to operations requiring operator intervention, such parts must be fitted with:

- fixed guards or interlocking movable guards preventing access to those sections of the parts that are notused in the work, and

- Adjustable guards as referred to in section 1.4.2.3 restricting access to those sections of the moving partswhere access is necessary.

When a part of the machinery has been stopped, any drift away from the stopping position, for whatever reasonother than action on the control devices, must be prevented or must be such that it does not present a hazard.

Where guards are designed to protect persons against the hazards generated bymoving transmission parts, are they either fixed guards or interlocking moveableguards ?

Yes No See notes

Are fixed guards used to protect persons against the hazards generated by moving

parts involved in the process, except for only those areas where access is deemed tobe frequent in which case are interlocking movable guards used ?

Yes No See notes

Risks of uncontrolled movements EHSR 1.3.9

When a part of the machinery has been stopped, any drift away from the stopping position, for whatever reasonother than action on the control devices, must be prevented or must be such that it does not present a hazard.

When the machine is stopped, is it prevented from making unexpected anduncontrolled movements?

Yes No See notes


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REQUIRED CHARACTERISTICS OF GUARDS AND PROTECTION DEVICES

General requirements

EHSR 1.4.1PUWER Regulation11

Guards and protective devices must:

- Be of robust construction.- Be securely held in place.- Not give rise to any additional hazard.- Not be easy to by-pass or render non-operational.- Be located at an adequate distance from the danger zone.- Cause minimum obstruction to the view of the production process, and- Enable essential work to be carried out on the installation and/or replacement of tools and for

maintenance purposes by restricting access exclusively to the area where the work has to be done, ifpossible without the guard having to be removed or the protective device having to be disabled.

In addition, guards must, where possible, protect against the ejection or falling of materials or objects and againstemissions generated by the machinery.

Are guards and protection devices adequate for their purpose, securely held in placeand sufficiently strong enough to contain any ejected objects?

If there is any possibility of liquids being ejected then guards must be designed andinstalled so that, as far as is reasonably practical, such liquids are prevented fromcausing a hazard by being contained within the guard.

Yes No See notes

Are guards or protection devices designed to not lead to additional hazards?Yes No See notes

Is it difficult for guards or protection devices to be bypassed and rendered non-operational?

Yes No See notes

Are guards and protection devices located at an adequate distance from the dangerzone?

Yes No See notes

Do guards and protection devices cause minimum obstruction to the view of theproduction process?

Yes No See notes

Are guards designed and positioned such that they do not hinder the carrying out ofessential maintenance work or machine adjustment such as replacement of tools,exchange of production changeover parts etc. without the guard having to be removedor the protective device having to be disabled?

Yes No See notes


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Special requirements for guardsEHSR 1.4.2PUWER Regulation 11

1.4.2.1 Fixed guardsFixed guards must be fixed by systems that can be opened or removed only with tools.Their fixing systems must remain attached to the guards or to the machinery when the guards are removed.Where possible, guards must be incapable of remaining in place without their fixings.

1.4.2.2 Interlocking movable guardsInterlocking movable guards must:

- As far as possible remain attached to the machinery when open.- Be designed and constructed in such a way that they can be adjusted only by means of an intentional

action.Interlocking movable guards must be associated with an interlocking device that:

- prevents the start of hazardous machinery functions until they are closed and- Gives a stop command whenever they are no longer closed.

Where it is possible for an operator to reach the danger zone before the risk due to the hazardous machineryfunctions has ceased, movable guards must be associated with a guard locking device in addition to an inter-locking device that:

- prevents the start of hazardous machinery functions until the guard is closed and locked, and

- Keeps the guard closed and locked until the risk of injury from the hazardous machinery functions hasceased.

Interlocking movable guards must be designed in such a way that the absence or failure of one of theircomponents prevents starting or stops the hazardous machinery functions.

1.4.2.3 Adjustable guards restricting accessAdjustable guards restricting access to those areas of the moving parts strictly necessary for the work must be:

- Adjustable manually or automatically, depending on the type of work involved. and- Readily adjustable without the use of tools.

Are fixed guards securely held in place with fixings which require tools for removal?Yes No See notes

Do the fixings which hold fixed guards in place remain attached to the guards or to themachinery when the guards are removed?

Yes No See notes

If possible, are fixed guards unable to remain in place without fasteners?Yes No See notes

Are moveable guards fixed to the machine when open?Yes No See notes

Are moveable guards interlocked with fail safe devices which give a stop commandwhenever they are no longer closed and prevent the start of hazardous machineryfunctions until they are closed?

Yes No See notes

Are moveable guards adjustable only with tools?

Yes No See notes


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Special requirements for protection devicesEHSR 1.4.3PUWER Regulation 11

Protective devices must be designed and incorporated into the control system in such a way that:- Moving parts cannot start up while they are within the operator's reach.- Persons cannot reach moving parts while the parts are moving, and- The absence or failure of one of their components prevents starting or stops the moving parts.

- Protective devices must be adjustable only by means of an intentional action.

Are moving parts prevented from starting up while they are within the operator's reach?Yes No See notes

Are all moving parts out of reach while the parts are moving?Yes No See notes

Are protective devices fail-safe?Yes No See notes

Are protective devices difficult to adjust unintentionally?Yes No See notes


24/37

RISKS DUE TO OTHER HAZARDS

Electricity SupplyEHSR 1.5.1PUWER Regulation 7

Where machinery has an electricity supply, it must be designed, constructed and equipped in such a way that allhazards of an electrical nature are or can be prevented.

The safety objectives set out in the Low Voltage Directive shall apply to machinery. However, the obligationsconcerning conformity assessment and the placing on the market and/or putting into service of machinery withregard to electrical hazards are governed solely by this Directive.

Does the machine comply with the requirements of BSEN 60204-1:2006: Safety ofmachinery - Electrical equipment of machines. Part 1 General requirements

Yes No See notes

Static electricityEHSR 1.5.2PUWER Regulation 7

Machinery must be designed and constructed to prevent or limit the build-up of potentially dangerous electrostaticcharges and/or be fitted with a discharging system.

Is the machine designed and constructed as to prevent or limit the build-up ofpotentially dangerous electrostatic charges and/or fitted with a discharging system?

Yes No See notes

Energy supply other than electricityEHSR 1.5.3PUWER Regulation 7

Where machinery is powered by source of energy other than electricity, it must be so designed, constructed andequipped as to avoid all potential risks associated with such sources of energy.

If the machine is powered by source of energy other than electricity e.g. hydraulic,pneumatic or thermal energy supplies, have the hazards associated with these beenconsidered?


Errors of fittingEHSR 1.5.4PUWER Regulation 7

Errors likely to be made when fitting or refitting certain parts which could be a source of risk must be madeimpossible by the design and construction of such parts or, failing this, by information given on the partsthemselves and/or their housings. The same information must be given on moving parts and/or their housingswhere the direction of movement needs to be known in order to avoid a risk.Where necessary. The instructions must give further information on these risks.Where a faulty connection can be the source of risk, incorrect connections must be made impossible by designor, failing this, by information given on the elements to be connected and, where appropriate, on the means ofconnection.

Where it is possible that errors made when fitting or refitting certain parts orconnections could be a source of risk, have measures been taken to prevent incorrectfitting?

Yes No See notes


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Extreme temperaturesEHSR 1.5.5PUWER Regulation 13

Steps must be taken to eliminate any risk of injury arising from contact with or proximity to machinery parts ormaterials at high or very low temperatures.The necessary steps must also be taken to avoid or protect against the risk of hot or very cold material beingejected.

Have steps been taken to eliminate any risk or injury caused by contact with orproximity to machinery parts or materials at high or very low temperatures?


Have steps been taken to prevent the risk of very hot or very cold material beingEjected?


FireEHSR 1.5.6PUWER Regulation 7PUWER Regulation 12

Machinery must be designed and constructed in such a way as to avoid any risk of fire or overheating posed bythe machinery itself or by gases, liquids, dust, vapors or other substances produced or used by the machinery.

Is the machine designed and constructed to avoid any risk of fire posed by the machineitself or by gases, liquids, dusts, vapours or other substances produced or used by themachine?

Yes No See notes

ExplosionEHSR 1.5.7PUWER Regulation 7PUWER Regulation 12

Machinery must be designed and constructed in such a way as to avoid any risk of explosion posed by themachinery itself or by gases, liquids, dust, vapors or other substances produced or used by the machinery.Machinery must comply, as far as the risk of explosion due to its use in a potentially explosive atmosphere isconcerned, with the provisions of the specific Community Directives.

Is the machine designed and constructed to avoid any risk of explosion posed by themachine itself or by gases, liquids, dusts, vapours or other substances produced orused by the machine?

Yes No See notes

Noise EHSR 1.5.8PUWER Regulation 7

Machinery must be designed and constructed in such a way that risks resulting from the emission of airbornenoise are reduced to the lowest level, taking account of technical progress and the availability of means ofreducing noise, in particular at source.The level of noise emission may be assessed with reference to comparative emission data for similar machinery.

Is there any noise insulation or other noise reduction techniques employed to reducethe noise level to a minimum?

Yes No See notes


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Vibration EHSR 1.5.9PUWER Regulation 7

Machinery must be designed and constructed in such a way that risks resulting from vibrations produced by themachinery are reduced to the lowest level, taking account of technical progress and the availability of means ofreducing vibration, in particular at source.The level of vibration emission may be assessed with reference to comparative emission data for similar

machinery

If the machine produces excessive vibration are measures in place to reduce vibrationto a minimum?

Yes No See notes

Radiation EHSR 1.5.10PUWER Regulation 7

Undesirable radiation emissions from the machinery must be eliminated or be reduced to levels that do not haveadverse effects on persons.Any functional ionising radiation emissions must be limited to the lowest level which is sufficient for the properfunctioning of the machinery during setting, operation and cleaning. Where a risk exists, the necessaryprotective measures must be taken.

Any functional non-ionising radiation emissions during setting, operation and cleaning must be limited to levelsthat do not have adverse effects on persons.

Is the machine EMC Compliant?Yes No See notes

Is the machine designed and constructed so that any emission of radiation is limited tothe extent necessary for its operation and that the effects on exposed persons are non-existent or reduced to non-dangerous proportions?

Yes No See notes

External radiation EHSR 1.5.11PUWER Regulation 7

Machinery must be designed and constructed in such a way that external radiation does not interfere with itsoperation.

Is the machine so designed and constructed that external radiation does not interferewith its operation?

Yes No See notes

Laser radiation EHSR 1.5.12PUWER Regulation 7

Where laser equipment is used, the following should be taken into account:- Laser equipment on machinery must be designed and constructed in such a way as to prevent any acci-

dental radiation.

- Laser equipment on machinery must be protected in such a way that effective radiation, radiation producedby reflection or diffusion and secondary radiation do not damage health.- Optical equipment for the observation or adjustment of laser equipment on machinery must be such that no

health risk is created by laser radiation.

Is the laser equipment designed and constructed to prevent any accidental radiation ?Yes No See notes


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Emissions of hazardous materials and substances EHSR 1.5.13PUWER Regulation 7

Machinery must be designed and constructed in such a way that risks of inhalation, ingestion, contact with theskin, eyes and mucous membranes and penetration through the skin of hazardous materials and substanceswhich it produces can be avoided.Where a hazard cannot be eliminated, the machinery must be so equipped that hazardous materials and

substances can be contained, evacuated, precipitated by water spraying, filtered or treated by another equallyeffective method.Where the process is not totally enclosed during normal operation of the machinery, the devices for containmentand/or evacuation must be situated in such a way as to have the maximum effect.

Is the machine designed, constructed and/or equipped so that risks due to gases,liquids, dust, vapours and other waste materials which it produces or uses can beavoided?

Yes No See notes

Risk of being trapped in a machine EHSR 1.5.14

Machinery must be designed, constructed or fitted with a means of preventing a person from being enclosedwithin it or, if that is impossible, with a means of summoning help.

Is the machine designed to prevent an exposed person from being enclosed within it or,if that is impossible, is there a means of summoning help?

Yes No See notes

Risk of slipping, tripping or falling EHSR 1.5.15

Parts of the machinery where persons are liable to move about or stand must be designed and constructed insuch a way as to prevent persons slipping, tripping or falling on or off these parts.Where appropriate, these parts must be fitted with handholds that are fixed relative to the user and that enablethem to maintain their stability.

Is the machine designed to prevent persons slipping, tripping or falling?Yes No See notes

LightningEHSR 1.5.16PUWER Regulation 7

Machinery in need of protection against the effects of lightning while being used must be fitted with a system forconducting the resultant electrical charge to earth.

If there is a risk of the machinery being struck by lightning, is a suitable systeminstalled for conducting the resultant electrical charge to earth?


Specific Risks / Specific HazardsPUWER Regulation 7PUWER Regulation 12

Have all identified specific risks been assessed by means of this document?If there are other specific risks not referred to in this document then a risk assessmentmust be carried out

Yes Risk Assessmentcarried out


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MAINTENANCE

Machinery maintenanceEHSR 1.6.1PUWER Regulation 5PUWER Regulation 22

Frequency of maintenance

Equipment may need to be checked frequently to ensure that safety-related features are functioning correctly. Afault which affects production is normally apparent within a short time; however, a fault in a safety-critical systemcould remain undetected unless appropriate safety checks are included in maintenance activities.

The frequency at which maintenance activities are carried out should also take into account the -

a) intensity of use - frequency and maximum working limitsb) operating environment, for example marine, outdoorsc) Variety of operations - is the equipment performing the same task all the time or does this change ?d) risk to health and safety from malfunction or failure

Maintenance management

The extent and complexity of maintenance can vary substantially from simple checks on basic equipment tointegrated programmes for complex plant. In all circumstances, for maintenance to be effective it needs to betargeted at the parts of work equipment where failure or deterioration could lead to health and safety risks.

Where safety-critical parts could fail and cause the equipment, guards or other protection devices to fail and leadto immediate or hidden potential risks, a formal system of planned preventative or condition-based maintenanceis likely to be needed.

Maintenance log

There is no requirement for a maintenance log to be kept. It is, however, recommended that a record ofmaintenance for high-risk equipment is kept.

A detailed maintenance log can provide information for future planning of maintenance activities and informmaintenance personnel and others of previous action taken.

If a maintenance log exists, it must be keep up to date.

Maintenance procedures should be carried out in accordance with any manufacturer's recommendations which

relate to the equipment, for example periodic lubrication, replacement and adjustment of partsMaintenance workers

Maintenance work should only be done by those who are competent to do the work. For details of the information,instructions and training required see also PUWER Regulations 8 and 9.

General maintenance requirements

If one or more of the following conditions cannot be satisfied for technical reasons, measures must be taken toensure that these operations can be carried out safely (see section 1.2.5) -

Adjustment and maintenance points must be located outside danger zones.

It must be possible to carry out adjustment, maintenance, repair, cleaning and servicing operations while

machinery is at a standstill.

In the case of automated machinery and, where necessary, other machinery, a connecting device for mountingdiagnostic fault-finding equipment must be provided.

Automated machinery components which have to be changed frequently must be capable of being removed andreplaced easily and safely. Access to the components must enable these tasks to be carried out with thenecessary technical means in accordance with a specified operating method.

Is the equipment maintained at an appropriate frequency? Yes No See notes

Are safety related features checked on a regular basis for correct functionality? Yes No See notes

Is a system of maintenance management in place?Yes No See notes

Can the machine be adjusted; lubricated and maintained safely from outside the dangerzones or whilst the machine is safely immobilised?

Yes No See notes


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Are safe working procedures in place for undertaking maintenance activities?Yes No See notes

Have all maintenance personnel received adequate training relating to Health andSafety and the safe use of equipment?

Yes No See notes

Is there an authorised persons list detailing who is competent to perform maintenancework?

Yes No See notes

Is there a record of maintenance undertaken e.g. a maintenance log, for the equipmentand if so is it kept up to date?

Note there is no requirement to have a maintenance log, however if one does exist thenit must be kept up to date. If no maintenance log exists then answer N/A.


Access to operating position and servicing points EHSR 1.6.2

Machinery must be designed and constructed in such a way as to allow access in safety to all areas whereintervention is necessary during operation, adjustment and maintenance of the machinery.

Is there safe means of access to all areas used for production, maintenance andadjustment?

Yes No See notes

Isolation of energy sourcesEHSR 1.6.3PUWER Regulation 19

Machinery must be fitted with means to isolate it from all energy sources. Such isolators must be clearly iden-tified. They must be capable of being locked if reconnection could endanger persons. Isolators must also becapable of being locked where an operator is unable, from any of the points to which he has access, to checkthat the energy is still cut off.In the case of machinery capable of being plugged into an electricity supply, removal of the plug is sufficient,provided that the operator can check from any of the points to which he has access that the plug remainsremoved.After the energy is cut off, it must be possible to dissipate normally any energy remaining or stored in the circuits

of the machinery without risk to persons.As an exception to the requirement laid down in the previous paragraphs, certain circuits may remain connectedto their energy sources in order, for example, to hold parts, to protect information, to light interiors, etc. In thiscase, special steps must be taken to ensure operator safety.

Can all energy sources be isolated by clearly identifiable and lockable devices?Yes No See notes

Can residual stored energy be dissipated safely without risk to persons.Yes No See notes

Operator intervention EHSR 1.6.4

Machinery must be so designed, constructed and equipped that the need for operator intervention is limited. Ifoperator intervention cannot be avoided, it must be possible to carry it out easily and safely.

Has the machine been designed to minimise the need for operator intervention?Yes No See notes


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Cleaning of internal parts EHSR 1.6.5

The machinery must be designed and constructed in such a way that it is possible to clean internal parts whichhave contained dangerous substances or preparations without entering them; any necessary unblocking mustalso be possible from the outside. If it is impossible to avoid entering the machinery, it must be designed andconstructed in such a way as to allow cleaning to take place safely.

Can the machine be cleaned without entering the danger zones or while the machineis immobilised? Yes No See notes

Training PUWER Regulation 9

Every employer shall ensure that all persons who supervise, manage or use work equipment have receivedadequate training for purposes of health and safety, including training in the methods which may be adoptedwhen using the work equipment, any risks which such use may entail and precautions to be taken.

What is 'adequate training?

It is not possible to specify what constitutes 'adequate training' as this varies with each individual person andeach different machine however as a general rule the following should be undertaken -

(a) evaluate of work equipment that they will use

(b) evaluate the competence they need to manage or supervise the use of work equipment; and(c) train the employee to make up any shortfall between their competence and that required to carry out the

work with due regard to health and safety.

When is training necessary?

Training needs are likely to be greatest on recruitment. However, training needs are also required:

(a) if the risks to which people are exposed change due to a change in their working tasks; or(b) because new technology or equipment is introduced; or(c) if the system of work changes.

Also, you should provide refresher training if necessary. Skills decline if they are not used regularly.

Pay particular attention to people who deputize for others on occasions - as they may need more frequentrefresher training than those who do the work regularly.

For the purposes of health and safety, have all operators and maintenance personnelreceived adequate training on the equipment and has a record of such training beenkept ?

Yes No See notes

Do formal training procedures exist for

new employees or employees who have never used the equipment before ?

employees who have moved from one area or department to another and who

have used similar or identical equipment before ?

Yes No See notes

`


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INFORMATION

Information and warnings on the machineryEHSR 1.7.1PUWER Regulation 23PUWER Regulation 24

Information and warnings on the machinery should preferably be provided in the form of readily understandable

symbols or pictograms. Any written or verbal information and warnings must be expressed in an officialCommunity language or languages, which may be determined in accordance with the Treaty by the MemberState in which the machinery is placed on the market and/or put into service and may be accompanied, onrequest, by versions in any other official Community language or languages understood by the operators.

1.7.1.1 Information and information devicesThe information needed to control machinery must be provided in a form that is unambiguous and easilyunderstood. It must not be excessive to the extent of overloading the operator.Visual display units or any other interactive means of communication between the operator and the machinemust be easily understood and easy to use.

1.7.1.2 Warning devicesWhere the health and safety of persons may be endangered by a fault in the operation of unsupervised

machinery, the machinery must be equipped in such a way as to give an appropriate acoustic or light signal as awarning.Where machinery is equipped with warning devices these must be unambiguous and easily perceived. Theoperator must have facilities to check the operation of such warning devices at all times.The requirements of the specific Community Directives concerning colours and safety signals must be compliedwith.

Are all warnings, signs, labels etc on the machinery in the language of the intendedmachine operator / end user?

Yes No See notes

Is information needed to control the machine unambiguous and easily understood?Yes No See notes

Are warning devices unambiguous, easily understood and easily checked for

operation?

Yes No See notes

Are any pipelines and vessels marked with their internal substances?Yes No N/A See notes

Are pipelines marked with direction of flow arrows?Yes No N/A See notes

Warning of residual risksEHSR 1.7.2PUWER Regulation 24

Where risks remain despite the inherent safe design measures, safeguarding and complementary protectivemeasures adopted, the necessary warnings, including warning devices, must be provided.

Such warnings should preferably use readily understandable pictograms and/or be drawn up in one of thelanguages of the country in which the machinery is to be used, accompanied, on request, by the languagesunderstood by the operators

Are there warnings for all residual risks and are such warnings in the language of thenormal machine operator ?

Yes No See notes


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InstructionsEHSR 1.7.4PUWER Regulation 8

All machinery must be accompanied by instructions in the official Community language or languages of theMember State in which it is placed on the market and/or put into service.

The instructions accompanying the machinery must be either 'Original instructions' or a 'Translation of theoriginal instructions', in which case the translation must be accompanied by the original instructions.By way of exception, the maintenance instructions intended for use by specialised personnel mandated by themanufacturer or his authorised representative may be supplied in only one Community language which the

specialised personnel understand.The instructions must be drafted in accordance with the principles set out below.

1.7.4.1 General principles for the drafting of instructions(a) The instructions must be drafted in one or more official Community languages. The words 'Original

instructions' must appear on the language version(s) verified by the manufacturer or his authorised repre-sentative.

(b) Where no 'Original instructions' exist in the official language(s) of the country where the machinery is tobe used, a translation into that/those language(s) must be provided by the manufacturer or his authorisedrepresentative or by the person bringing the machinery into the language area in question. The transla-tions must bear the words 'Translation of the original instructions'.

(c) The contents of the instructions must cover not only the intended use of the machinery but also take intoaccount any reasonably foreseeable misuse thereof.

(d) In the case of machinery intended for use by non-professional operators, the wording and layout of theinstructions for use must take into account the level of general education and acumen that can reasonablybe expected from such operators.

1.7.4.2 Contents of the instructionsEach instruction manual must contain, where applicable, at least the following information:

(a) the business name and full address of the manufacturer and of his authorised representative;(b) the designation of the machinery as marked on the machinery itself, except for the serial number (see

section 1.7.3);(c) the EC declaration of conformity, or a document setting out the contents of the EC declaration of confor-

mity, showing the particulars of the machinery, not necessarily including the serial number and thesignature;

(d) a general description of the machinery;

Marking of Machinery EHSR 1.7.3

All machinery must be marked visibly, legibly and indelibly with the following minimum particulars:- The business name and full address of the manufacturer and, where applicable, his authorised

representative.- Designation of the machinery.- The CE Marking (as reproduced here from Annex III).

- Designation of series or type.- Serial number, if any.- The year of construction, that is the year in which the manufacturing

process is completed.It is prohibited to pre-date or post-date the machinery when affixing the CE marking.Furthermore, machinery designed and constructed for use in a potentially explosive atmosphere must bemarked accordingly.Machinery must also bear full information relevant to its type and essential for safe use. Such information issubject to the requirements set out in section 1.7.1.Where a machine part must be handled during use with lifting equipment, its mass must be indicated legibly,indelibly and unambiguously.

Is the machine either

not CE marked because of its age (i.e. manufactured before 1st

January 1995) or marked visibly, legibly and indelibly with the minimum particulars as listed above

Yes No See notes


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1.7.4.2 Contents of the instructions (continued)

(e) the drawings, diagrams, descriptions and explanations necessary for the use, maintenance and repair ofthe machinery and for checking its correct functioning;

(f) a description of the workstation(s) likely to be occupied by operators;(g) a description of the intended use of the machinery;(h) warnings concerning ways in which the machinery must not be used that experience has shown might

occur;(i) assembly, installation and connection instructions, including drawings, diagrams and the means of attach-

ment and the designation of the chassis or installation on which the machinery is to be mounted;(j) instructions relating to installation and assembly for reducing noise or vibration;(k) instructions for the putting into service and use of the machinery and, if necessary, instructions for the

training of operators;(l) Information about the residual risks that remain despite the inherent safe design measures. safeguarding

and complementary protective measures adopted;(m) Instructions on the protective measures to be taken by the user, including. where appropriate, the

personal protective equipment to be provided;(n) the essential characteristics of tools which may be fitted to the machinery;(o) The conditions in which the machinery meets the requirement of stability during use, transportation,

assembly, dismantling when out of service. testing or foreseeable breakdowns;(p) instructions with a view to ensuring that transport, handling and storage operations can be made safely,

giving the mass of the machinery and of its various parts where these are regularly to be transported

separately;(q) the operating method to be followed in the event of accident or breakdown, if a blockage is likely to occur,

the operating method to be followed so as to enable the equipment to be safely unblocked;(r) the description of the adjustment and maintenance operations that should be carried out by the user and

the preventive maintenance measures that should be observed;(s) instructions designed to enable adjustment and maintenance to be carried out safely, including the

protective measures that should be taken during these operations;(t) the specifications of the spare parts to be used, when these affect the health and safety of operators;(u) the following information on airborne noise emissions:

- The A-weighted emission sound pressure level at workstations, where this exceeds 70 dB(A); wherethis level does not exceed 70 dB(A), this fact must be indicated.

- The peak C-weighted instantaneous sound pressure value at workstations, where this exceeds 63Pa (130 dB in relation to 20 Pa).

- the A-weighted sound power level emitted by the machinery, where the A-weighted emission soundpressure level at workstations exceeds 80 dB(A).

These values must be either those actually measured for the machinery in question or those establishedon the basis of measurements taken for technically comparable machinery which is representative of themachinery to be produced.In the case of very large machinery, instead of the A-weighted sound power level. the A-weighted emis-sion sound pressure levels at specified positions around the machinery may be indicated.Where the harmonised standards are not applied, sound levels must be measured using the most appro-priate method for the machinery. Whenever sound emission values are indicated the uncertaintiessurrounding these values must be specified. The operating conditions of the machinery during measure-ment and the measuring methods used must be described.Where the workstation(s) are undefined or cannot be defined, A-weighted sound pressure levels must bemeasured at a distance of 1 metre from the surface of the machinery and at a height of 1.6 metres fromthe floor or access platform. The position and value of the maximum sound pressure must be indicated.Where specific Community Directives lay down other requirements for the measurement of sound pres-sure levels or sound power levels, those Directives must be applied and the corresponding provisions ofthis section shall not apply;

(v) Where machinery is likel

Combined EHSRand PUWER

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