Risk Assessment for a Machine Modification

if it’s your first rodeo so to speak... off hand, I’ll just use experience...

1.) Ask yourself why is this machine being modified? And it’s overall impact on to all entities.

• make it more efficient
• Update the safety issues
• make it follow other standards
• make it more versatile (such as using it for running other product types???)
• easier maintenance

2.) what is the impact?

• any changes, How does it affect maintenance, make it easier or more difficult if not address in 1.)
• will it be more productive, and how much more (speculative)
• will it preform better

You basically have to look at where you are, the goals where you want to be as well as the ROI for the upgrade (justification).

I'm sure there’s more, but with the information you supply,... I don’t have any more time to drill it down further.

Thanks for reply.

I will rephrase the question. Does anybody has a template so that I could follow and fulfill it?

I know why I do a modification and what are benefits. It is just to have a template of risk assessment

In machine design for safety, these are the things that I take into consideration:

1. Identify the potential hazards that require protection
2. What are the relevant codes and legal requirements
3. How my design will effect the operation and maintenance of the machine
4. What effect will my design have on the productivity of the process
5. what are the failure modes of my design

What are the things that could possibly go wrong because of the modification....What steps have I taken to prevent those things from happening....

Thank you very much. This is something that I need so that I can start off building for my purphose

Just having a template seems lacking, although useful. You should familiarize yourself with your local safety standards. In the US we reference ANSI B11.19 - 2010 and ANSI R15.06 - 2012. Both also reference the relevant ISO standards, industrial safety rules are becoming global.

I can't share my employer's template but it references ISO 14121-1:2007 and ISO 12100-1:2003 and ISO 1200-2:2003 for examples of hazards.

Our template is an Excel file that helps us score the various hazards to identify what level of performance our safety devices should have. I don't believe we started from scratch so maybe there's something similar out there. I would search web sites of safety hardware companies like PILZ, Euchner, et. al.