15/02/2021

Machine Safety Training Course Module 3

Prevention of Machinery Hazards
TÜV Rheinland
Training Master

Risk Estimation, Evaluation and Reduction

Honda Prospect Motor Feb 2021
Trainer: Ivan Stevanus Chandra

Module 3: Risk Estimation, Evaluation and Reduction

Welcome to TÜV Rheinland Academy

Introduction to Machinery Safety
2021

1
 15/02/2021

The aim of this course

Is to understand and be able to:

Principle of Risk Assessment

HM Formula Risk Assessment

Method for Risk Estimation and

Evaluation

Quantification of Risk

Risk Priority Number/

Risk Rating - HPM

Application of HAZARD Hierarchy Control

Machinery Safety Risk Assessment

2
 15/02/2021

Key learning for Applying Hazard Hierarchy Control

Improvement on Risk Reduction

Design Based Engineering Information to use or PPE

Conceptual Measurement. Technical Control Administrative control Last Choice of Counter
Measurement. Human and Machine Measure.
Interaction.

Inherently Safe Design

Top Level of Hierarchy of Control

Intensification
 Using Smaller Quantities

Substitution
 Using lesser hazardous materials

Attenuation (Reduction)
 Using less hazardous conditions or
 Less hazardous forms of the material

Limitation of effects
 Designing the facility to minimize affects
It is better to avoid or eliminate a hazard instead of trying to control it.
Simplification
 Designing facilities to reduce the chance of operating errors

3
 15/02/2021

Engineering Control
Technical Measurement

Passive Control Measure

 Measures which have an immediate impact without relying on
human, mechanical or electronic action
i.e. Blocked walls or Cage; safety distance.

Active Control Measures

 Measures which rely on mechanical or electrical devices to take the
proper action to control a hazard
i.e. Fire Protection System

Mechanical Devices
i.e. hydraulic or pneumatic closing gate

I/E Devices
i.e. Movement Sensors

Information for Use and Administrative Control

Organizational Measurement

Information for use/Safety label must follows three principles:

 Identify the hazard
 Identify the likely degree of injury that could occur
 Instruct the reader about ways to avoid injury

Administrative Control Measures

 Measures which involve the correct and timely actions of
personnel to control a hazard
 Examples of Administrative Controls:
i.e. Operating Procedures/ Checklists
i.e. Safe Work Permits
i.e. Training Programs
i.e. i.e. Safety Inspection/ Walk-throughs

4
 15/02/2021

PPE – Personal Protective Equipment

Lowest Control Measurement

PPE as basic tenues for workers:

 Helmet
 Safety glasses
 Safety Shoes
 Long sleeves or coverall clothes.

Hot issues on PPE

 Poorly fitted/maintained
 Improperly used – need training
 Inconsistency for application due to comfort usage

Module 3
Risk Assessment – HM Formula

5
 15/02/2021

Start – Define The Issue (1)

General

Performing Machine Risk Assessment:

1. Collect information and define the limits of the machine.
 Identification Machine/Process.
 Use common sense and global view

Machine/Process under Review shall be checked as follows:

- Target Function
- Condition of use
- Operate/use
- Features
- Requirements (see legal aspects)

2. Address one machine into at least one function or several

functions (depend on the observation).
 Collect and list the actual/present safety measure

Start – Define The Issue

Collect information

Checklist of potentially useful

information for carrying out a risk
assessment :
1. Drawings/Process Operation (PFD),
Calculation, accident Data, Machine-specific
literature etc.

2. Machine Limits such as

 Nature and characteristics of machine.
 Operating environment of the machine
 Type of user
 Working methods throughout life cycle of the
machine

6
 15/02/2021

Start – Define The Issue

Practical with HM Formula in Risk Assessment

Filled No. 1-5

1. Process Name
2. Type of Work
3. Content of Work
4. Frequency
5. Working Condition

Machine Hazard Identification (2)

Use type A, B and C according to Harmonized EU Standard

Performing Hazard identification:

1. Identify the latent hazard related to the machine.
 Identification Machine/Process.
 Use common sense and global view

Machine/Process under Review shall be checked as follows:

- Target Function
- Condition of use
- Operate/use
- Features
- Requirements (see legal aspects)

Address one machine into at least one function or several functions (depend on
the observation).

7
 15/02/2021

Machine Hazard Identification

Practical with HM Formula in Risk Assessment

Performing Hazard
Identification or No. 6:
 Forecast and describe what kinds
of hazards and phenomena
causing disasters.
1. Mechanical hazards
2. Electrical hazards
3. Thermal hazards
4. Hazards generated by noise
5. Hazards generated by vibration
6. Hazards generated by radiation
7. Hazards generated by materials
and substances
8. Hazards generated by the neglect
of ergonomic principles in the
design of machinery

Danger Level
Practical with HM Formula in Risk Assessment

Performing Risk Estimation and Risk Evaluation No.8:

1. Possibility of Injury
2. Severity of Injury Level of Danger
3. Frequency of Danger

8
 15/02/2021

Evaluation Criteria
Practical with HM Formula in Risk Assessment

If condition of rank
CHANCE Risk Rating potentially Rank A / B
CONSEQUENCE Safety Committee will be
I II III IV A = Extreme judgement the condition of
new machinery &
I 1 2 3 4 B = High equipment for stop
production. If rank condition
II 2 4 6 8 is C / D machine can be
C = Medium used but need to control and
III 3 6 9 12 monitor.
D = Low
IV 4 8 12 16
Explanation
Kategori
Chance Consenquence Rank Risk Countermeasure
An accident will not occur on the normal
HS Scratch wound A = 12 – 16
condition Stop or improve the work methods as soon as
I I Can not be
Minimum impact and can recoverable possible
E Every decade (almost none) allowed to happen
immediately
An accident will occur if the employee Improve the work methods, if with technology
HS Minor injury (without work days off) B = 6–9
careless can not be avoided, then with the permission
II II There is a serious
Limited impact and can recoverable from the safety and environmental manager, give
E Every year (less likely) problem
within a certain period a warning as an important subject
When the normal concentration can
HS Severe / major injury (work days off) C=3–4
occur an accident Give a warning and training, give a suggestion to
III III There is a
The impact causes environmental make the improvements with current technology
E Every month (there is a possibility) problem
damage on the site
An accident occur although the
HS A big accident (fatality / died) D=1–2
employee in full concentration Give a guidance and training, show the warning
IV IV There is a little
The impact causes enviromental indications in the standard work table
E Every day (high probability) problem
damage until the outside area

Machine Hazard Identification

Practical with HM Formula in Risk Assessment

Before Countermeasure or
No. 11:
 Generally considered as Raw Risk

9
 15/02/2021

Machine Risk Estimation and Risk Evaluation(2)

Practical with HM Formula in Risk Assessment
No. 12: Explanation of Countermeasure available

No. 13: Degree I to V

No. 14: Degree of danger after applying the

current countermeasures.

No. 15: Put number by chance and consequence.

No. 16: Put the evaluation of RA as

 5: feasible
 4: Enabled if you make efforts
 3: Difficult but possible
 2: Very difficult
 1: Impossible

Coffeebreak

10
 15/02/2021

Workshop for Risk Assessment

Application Risk Assessment with HM Formula

Risk Assessment Back Bone Methodology

Process Flow Diagram Block diagrams

Understand Process/ Each task properly identify the

Divide/ Segregate based on
Activity in your Working hazard and how it is involved
Logical or Proper task
Area with HMI

Evaluate the ”Raw Risk”

with “high rank” against First Assessment on “Raw Determine Probability/ Chance
“safety measures”  Risk” and collect the available Severity/ Consequence and
Acceptable or Not? safety measures Level of Danger

Second Assessment on “After Classify the “High Rank Risk”

counter measure level” and in the Lis of Critical Activity
review the feasibility For further socialization

Process Flow to do Risk Assessment and how to Reduce the Risk in your Daily Activity

11
 15/02/2021

Action to do
Perform Risk Assessment using HM Formula

Workshop Begin:
 Generally considered as Raw Risk

HOW LONG
does it take for a plastic
bottle to decompose?

12
 15/02/2021

Thank You for Your Attention

Risk Estimation, Evaluation and Reduction

Compliance with ISO 12100, 2010

Ivan Stevanus Chandra

Jakarta, 17-18 February 2021

www.tuv.com

LEGAL DISCLAIMER
This document remains the property of TÜV Rheinland. It is supplied in confidence solely for information purposes for the recipient. Neither this
document nor any information or data contained therein may be used for any other purposes, or duplicated or disclosed in whole or in part, to any
third party, without the prior written authorization by TÜV Rheinland. This document is not complete without a verbal explanation (presentation)
of the content.
TÜV Rheinland AG

13