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Improve machine safety with an NHP and AS4024 risk assessment template

If you’re a business owner, it’s important to review your site documentation and assess risk and hazards. This evaluation checklist can help you do just that. By reviewing your site documentation, assessing the risks posed by hazards, and evaluating machine operational safety limits, you can provide advice to third parties on how to improve the overall safety of their plant, equipment, and machinery.

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Audit
Document Revisions
Document Revisons
Revised By?
Date of Revision
Signature of Document Editor
Site Documentation viewed
Electrical Drawings
Hydraulic Circuits
Pneumatic Circuits
Mechanical Layouts
Operating manuals
Maintenance Manuals
Safety Instructions
Material Safety Data Sheets
Site or Plant Contacts
Personnel Interviewed About Machinery
Name
Position
Purpose of this Assessment
Purpose of this assessment is to provide the recipient company with advice and guidance relating to the safety of the plant, equipment or machinery being assessed. All relevant Australian and European standards applicable will be used to assess each hazard.
Motivation of Company requesting this assessment
Service Provided
The risk assessment model being used is a widely acceptable form of examination for plant, equipment or machinery and work practices. The approach is a standardized set of approaches governing hazard identification, evaluating that risk posed to personnel. The assessment will give the reader an informed view on how likely a hazard would be to occur and what could be done to mitigate against the hazard occurring in the future.
Phases of machine operation being assessed
Transport
Cleaning
Maintenance / Repair
De-commisioning
Operation
Disposal
Installation
Assembly / Installation
Basic Machine Limits
Manufacturer / OEM
Machine Importer or supplier
Machine Name
Machine Serial Number
Are operators trained to use equipment?
Who is responsible for maintenance & repair?
Who is responsible for cleaning and clearing of jams etc?
Are maintenance staff trained on equipment?
What is the normal maintenance interval?
Is machine being used in it's intended environment?
Basic Description of Control System
What is the control voltage?
What is the main power supply voltage?
Does the machine have Hydraulic Controls
What is the Hydraulic Pressure in Bar?
Does the machine have Pneumatics controls?
What is the Compressed Air Pressure in Bar?
Details relating to hazard and tasks
Description of all Hazards
Photograph of Hazard
Area of Machine associated with hazard?
Task or operation?
Types of Hazards associated with the task?
Hazard Description
Hazard Rating Number - multiply DPH x FE x LO x NP to get HRN - the number determines the Risk Level.
DPH - Degree of Possible Harm
FE - Frequency of Exposure
LO - Likelihood of Occurance
NP - Number of Persons affected / in hazardous area
HRN - Hazard Rating Number ( LO x FE x DPH x NP = HRN)
Residual Risk Reduction
Residual Risk Reduction Measures
DPH - Degree of Possible Harm after Risk Reduction
FE - Frequency of Exposure after Risk Reduction
LO - Likelihood of Occurrence after Risk Reduction
NP - Number of Persons affected / in hazardous area
HRN - Hazard Rating Number ( LO x FE x DPH = HRN) after Risk Reduction
Category of Control required (AS4024.1501:2014) if Guarding solution requires SRP/CS and not just a mechanical guarding.
Severity of Hazard
AS4024.1-2014 Category B+1 Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned. Category 1 - Well Tried Safety Components and principles - widely used with successful components, made and verified for use in safety circuits.
Frequency of Hazardous Event
Possibility of Avoiding the Hazard(s)
AS4024.1-2014 Category 1 (with over-dimensioning and Fault exclusion) or Category 2 Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned. Category 1 - Well Tried Safety Components and principles - widely used with successful components, made and verified for use in safety circuits. OR Category 2 - Category B shall apply + safety functions shall be checked by the machine control system at suitable intervals. If manual checks are performed then this should be documented. Check shall generate a fault indication if a fault is detected
AS4024.1-2014 Category 2 (with over-dimensioning and Fault exclusion) or Category 3 Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned. Category 2 - Category B shall apply + safety functions shall be checked by the machine control system at suitable intervals. If manual checks are performed then this should be documented. Check shall generate a fault indication if a fault is detected OR Category 3 - Category B shall apply + shall be designed so that a single fault in any part of the SRP/CS does not lead to a loss of safety function. Wherever reasonably practicable, the single fault shall be detected at or before the next demand upon the safety function.
Possibility of Avoiding the Hazard(s)
AS4024.1-2014 Category 3 Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned. Category 3 - Category B shall apply + shall be designed so that a single fault in any part of the SRP/CS does not lead to a loss of safety function. Wherever reasonably practicable, the single fault shall be detected at or before the next demand upon the safety function.
AS4024.1-2014 Category 4 Category B - Well Tried Principles - components - designed and constructed to withstand expected influences. Be correctly protected and dimensioned. Category 4 - Category B shall apply + a single fault in SRP/CS does not lead to loss of safety function and the single fault is detected at or before the next demand of the safety functions i.e. immediately or at the end of the machine operating cycle. If detection is not possible then an accumulation of faults shall not lead to a loss of safety function.
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Evaluation checklist for the efficiency and safety of your business


There are a number of hazards that can occur during plant operations, and it’s important for businesses to be aware of them. By using this evaluation checklist, you can help identify and assess risks and hazards, as well as evaluate machine operational safety limits and guarding strategies in accordance with NHP and AS4024.1:2014 standards. This will help ensure that your plant is safe from potential accidents or injuries.


The following are some tips for using this checklist:


  • Start by reviewing your current site documents (safety briefing sheet [SBS], work procedure document [WPD]), which will include important information about risks and hazards at your plant. This will help you identify potential areas where improvements or changes may be needed in order to comply with regulations
  • Next conduct a machine risk assessment based on specific tasks that need to be performed at your facility (e.g., grinding/milling operations). Once the risks associated with specific tasks have been determined, create appropriate safeguards accordingly (i.e., use personal protective equipment [PPE] when necessary; set maximum operating limits; implement guarding measures).
  • Finally, update any SBSs or WPs as needed in order to continue providing safe working conditions for employees
  • Please note that this checklist template is a hypothetical appuses-hero example and provides only standard information. The template does not aim to replace, among other things, workplace, health and safety advice, medical advice, diagnosis or treatment, or any other applicable law. You should seek your professional advice to determine whether the use of such a checklist is appropriate in your workplace or jurisdiction.