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Machinery risk assessment template

An Excel template for risk assessment to EN ISO 12100

Download a free Excel template for machinery risk assessment. The columns follow EN ISO 12100, the risk is estimated with the hybrid method of ISO/TR 14121-2, and three rows are filled in as examples.

Try it freeDownload the template

The columnsOne row per hazardous situation.

  1. 01

    Life phase

    Transport, installation, commissioning, setting, operation, cleaning, maintenance, fault finding or decommissioning.

  2. 02

    Task

    What the person does at the machine, such as changing a tool or clearing a jammed blank.

  3. 03

    Hazard and type

    What can cause harm, such as a moving part or a live busbar, and which group of Annex B it belongs to.

  4. 04

    Hazardous situation

    When a person is exposed to the hazard, and what happens.

  5. 05

    Risk before the measure

    Severity, exposure, probability and avoidance, with the class and risk level.

  6. 06

    Protective measure and type

    Inherent design, safeguarding, personal protective equipment or information.

  7. 07

    Risk after the measure

    The same four numbers with the measure in place, so you can see what it does.

  8. 08

    PLr and safety function

    The risk graph of EN ISO 13849-1 when the measure is a safety function, and what the function as built achieves.

Three examplesA robot cell that loads and unloads a press brake.

Maintenance · Mechanical

Change the fingers on the robot's gripper

Hazard
Movement of the robot
Hazardous situation
The operator is inside the cell at the gripper when the robot starts, and can be struck or crushed against the press table.
Protective measure · Safeguarding
A fixed guard round the cell and an interlocked door with guard locking, which stops the robot before the door can open.

BeforeHigh 9

AfterMedium 5

PLrd

Setting · Mechanical

Set the back gauge

Hazard
Movement of the ram
Hazardous situation
The setter has their fingers between the upper and lower tools when the press starts by mistake.
Protective measure · Safeguarding
A setting mode with creep speed and a two-hand control. In that mode the robot cannot start the press.

BeforeMedium 8

AfterLow 5

PLrc

Fault finding · Electrical

Fault-find in the control cabinet

Hazard
Live parts
Hazardous situation
The electrician measures with the cabinet open and touches a 400 V busbar.
Protective measure · Safeguarding
Finger-safe covers over live parts in the cabinet and a sign to isolate the supply before work.

BeforeMedium 7

AfterMedium 6

In the third example the level stays medium: the cover lowers the class but not the severity. That risk belongs in the instructions for use.

The scalesThe hybrid method of ISO/TR 14121-2. The class is exposure, probability and avoidance added up.

Severity

  • 1 · First aid is enough
  • 2 · Medical treatment, fully healed
  • 3 · Permanent, such as a lost finger
  • 4 · Death, loss of an arm or of sight

Frequency of exposure

  • 1 · Less than once a year
  • 2 · A few times a year
  • 3 · Every two weeks or more often
  • 4 · Daily
  • 5 · Hourly or more often

Probability

  • 1 · Negligible
  • 2 · Rare
  • 3 · Possible
  • 4 · Likely
  • 5 · Very high

Possibility of avoidance

  • 1 · Likely
  • 3 · Rarely possible
  • 5 · Impossible

Risk level by severity and class

Severity \ Class3–45–78–1011–1314–15
4MediumMediumHighHighHigh
3LowLowMediumHighHigh
2LowLowLowMediumHigh
1LowLowLowLowMedium

How to use the templateIn the same order as EN ISO 12100.

  1. 01

    Write down the machine's limits

    Intended use, reasonably foreseeable misuse, and limits of space and time, before the first row.

  2. 02

    Go through every life phase

    One row per hazardous situation. Setting, cleaning and fault finding get as much time as operation.

  3. 03

    Estimate before and after

    The same four numbers both times. Delete the examples once you've seen how they're filled in.

  4. 04

    Approve and keep it

    Version, date and who approved it. Carry the residual risks over into the instructions for use.

Let Verkio suggest the rowsThe same columns, filled in from your documents.

Verkio reads the machine's manuals, drawings and reports and suggests rows for every life phase, with an estimate before and after and the page each suggestion rests on. You approve, edit or reject every row.

The template has the same columns as the risk register in Verkio. A filled-in template can be imported, and each row becomes a draft to review.

Common questionsAbout the template.

Does the template cost anything?

No. It's free to download and use, with no account.

Is the template a risk assessment on its own?

The template is a register. The risk assessment is the work behind the rows: the limits, going through every life phase and deciding on the measures. The register documents that work.

Why the hybrid method and not a risk matrix?

The hybrid method splits probability into exposure, the hazardous event and avoidance, so you can see what a measure actually changes. If you already use another method, the columns can be swapped.

Does it work in Google Sheets and Numbers?

Yes. The file is a plain .xlsx without macros.