Machine Risk Assessment Template – Free PDF

Machine risk assessment template

You can use this machine risk assessment template to identify hazards, evaluate risks, and assign controls for all types of machinery across your sites. It supports you in documenting inspections and tracking corrective actions as well as maintaining regulatory compliance. You’ll be able to reduce unplanned downtime and keep teams better protected during daily operations.

Eurostat reports that over a quarter of all fatal workplace accidents in the EU are caused by loss of control over machinery, tools, or handling equipment. If you need to assess risks beyond machines, check out our fire, COSHH, or dynamic risk assessment templates too for other use cases.

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Preview of the template

Page 1

Machine Information

Machine Name

Machine Model

Machine Serial Number

Machine Location

Machine Manufacturer

Machine Age (years)

Safety Features

Are all guards and protective devices in place and functioning properly?

Are emergency stop buttons clearly marked and accessible?

Are warning labels and signs clearly visible?

Is machine lockout/tagout procedure in place and followed?

Are operator training records up-to-date?

Mechanical Hazards

Are there any exposed moving parts that could cause entanglement?

Are there any pinch points that could cause crush injuries?

Are loads or components adequately supported to prevent falling hazards?

Are there any cutting or shearing edges that could cause lacerations?

Are machine stability and tipping hazards properly addressed?

Electrical Hazards

Are electrical panels and components properly enclosed and labeled?

Are electrical cords and cables in good condition and not creating tripping hazards?

Is the machine properly grounded to prevent electric shock?

Are proper lockout/tagout procedures in place for electrical maintenance?

Are the machine's electrical systems regularly inspected and maintained?

Environmental Considerations

Is the machine located in a well-ventilated area to control air quality?

Is the machine's noise level within acceptable limits?

Are there proper lighting conditions around the machine?

Is the machine placed on a stable, level surface to prevent tipping?

Are there any environmental conditions that could affect the machine's operation?

Maintenance and Inspections

Is a preventive maintenance program in place for the machine?

Are maintenance records and logs kept up-to-date?

Are scheduled inspections being performed and documented?

Are replacement parts and supplies readily available?

Is the machine shutdown and locked out prior to maintenance activities?

Overall Risk Assessment

What is the overall risk level associated with this machine?

Provide a brief summary of the key risks and recommendations for mitigation

Frequently asked questions

How do you perform a machine risk assessment?

Key steps include identifying hazards related to each machine, assessing the severity and likelihood of each risk, implementing appropriate control measures, documenting findings, and reviewing the assessment regularly. Involve operators in the process as well to capture real-world risks and ensure controls are practical.

What types of hazards are most commonly found during machine risk assessments?

Common hazards include moving parts that can cause entanglement, cutting or crushing injuries, electrical faults, hot surfaces, unexpected machine start-up, and exposure to hazardous substances. Poor maintenance and lack of guarding are also frequent issues that increase risk.

What are some effective control measures for common machine hazards?

Effective controls can include machine guarding, lockout/tagout procedures, emergency stops, safety interlocks, warning signs, and personal protective equipment. Training staff on safe use and maintenance is also critical to reduce the risk of accidents.

What should you do if a new machine is installed on site?

Make sure to complete a new risk assessment before using the machine. This includes reviewing manufacturer’s safety information, training staff, and integrating the new equipment into existing safety procedures. This step helps identify unique hazards and implement controls from the start.

This template, developed by Lumiform employees, serves as a starting point for businesses using the Lumiform platform and is intended as a hypothetical example only. It does not replace professional advice. Companies should consult qualified professionals to assess the suitability and legality of using this template in their specific workplace or jurisdiction. Lumiform is not liable for any errors or omissions in this template or for any actions taken based on its content.