Spreadsheet: 802371d1666808107-formula-to-filter-data-question-haz-control-budget-trial
Sheet: Risk Assessment

NOTES |  |  |  |  | Filtering details
Yellow highlight are options to be decided on. |  |  |  |  | Lower Risk Reduction threshold |  |  |  |  | 5
Green highlight are non very high risk but will complete the machine safety control requirements |  |  |  |  | Lower Current Risk Score threshold |  |  |  |  | 18
Red text are non-compliant controls with the residual risk to be accepted. |  |  |  |  | -
Blue text are PPE controls and these controls alone will not reduce the risk score to rare due to ease of defeat
NIL budget are controls that are already underway with the Engineering team
M = Mechanical FS = Electrical/Functional Safety A = Administrative M/FS = Mech/Elec/FuncSafe Main = Engineering/Maintenance Team
GENERAL SAFETY CONTROL REQUIREMENTS
Fixed guarding | Fixed guarding mesh to be <30mm or smaller depending on the reach distances from AS/NZS 4024.1801 Table 4 or a relevant Type C standard
 | Fasteners must require a unique tool to remove(such as safety fasteners). The unique tool  shall only be provided to authorised persons under PTW system (Generally, engineering and maintenance staff only).
 | Review AS/NZS 4024.1601 for all requirements
Emergency Stops | E-STOPS shall not be used to process stop or lock out the machine
 | E-STOPS must meet a minimum of PLc and are only to be used as a complimentary safety device to othe safety controls
 | All E-STOPS actuators should be safety tested every 6 months as a minimum. Recommend functional testing in the pre-start checks weekly as a minimum.
 | E-STOP shall be located at each operator control station and work position
 | E-STOP buttons/lanyards are not to be shrouded, are recommeded for have >50[NAME] clerance around the button for hand/palm access, and inadvertant activation should not impair its accessibility
 | E-STOP actuators that require a key to unlatch shall not have the key permanently in the keyhole.
 | E-STOP lanyards shall have between 75mm and 150[NAME] deflection before activation and shall be activated in all directions including pulling towards the actuator (e.g. spring on the non-actuator end)
 | Review AS/NZS 4024.1604 for all requirements
Interlocks | Defeat of an interlock in a reasonably foreseeable manner shall be prevented (e.g. taping down plunger, inserting spare pin)
 | Location of an interlock shall be protected from foreseeable damage
 | Location of an interlock shall activate before any gaps allow reach into the hazard
 | The time to reach that hazard after activation of an interlock shall be less than the hazardous movement stopping time. If not, repositioning of the interlocked guard or a locking interlock or a method to delay entry after activation of the interlock shall be fitted
 | Interlocks shall be operated in the positive direction (failure to safe state) (e.g. plunger switches with springs shall require the guard to push the actuator in when opening)
 | Review AS/NZS 4024.1602 for all requirements
Machine | [NAME] | Filter | Discipline | Control | Current Score | Residual Score | Risk Reduction | Budget | Selected Low Risk | 18 | Comments
PCS 3800 | Transmission hazards |  | M | Fit fixed guarding over the  rack and pinion on both sides of the bridge | 18 | 14
 | Pneumatic hazards |  | Main | (1) Replace sharkbite fittings as part of PMs | 15 | 14 |  | 500
 | [NAME] hazards |  | Main | (1) See [NAME] hazard controls | 18 | 14
 | Moderate impact to body/arms as the bridge & carriage transverses automatically during normal operator and troubleshooting |  | FS | (1) Modify the E-STOP lanyards to fully suround the bridge and fit a spring to the non-actuator end to allow activation in all directions. Ensure the reset of the lanyard requries the operator to have direct visual contact along the lanyard path before resetting, sequencial resets may be requried if the lanyard extends around a corner | 12 | 7 |  | 3000
 |  |  | FS | (1) Fit a reset buton to the main control panel | 12 | 7 |  | 500
 |  |  | FS | (1) Fit a visual indicator when the machine can move automatically | 12 | 7 |  | 500
 |  |  | FS | (1) Fit a buzzer to sound for 3s before automatic movement | 12 | 7 |  | 500
KOIKE SANSO-KOGYO 1 | Transmission hazards |  | M | Fit roller guards over the guide rollers and drive sprocket | 21 | 14 |  | 1000
 | Pneumatic hazards |  | Main | (2) Replace sharkbite fittings as part of PMs | 15 | 14 |  | 500
 | [NAME] hazards |  | Main | (2) See [NAME] hazard controls | 18 | -
 | Moderate impact to body/arms and crush to hands/arms as the carriage transverses automatically during normal operator and troubleshooting |  |  | (2) Modify the E-STOP lanyards to fully suround the bridge and fit a spring to the non-actuator end to allow activation in all directions. Ensure the reset of the lanyard requries the operator to have direct visual contact along the lanyard path before resetting, sequencial resets may be requried if the lanyard extends around a corner | 17 | 7
 |  |  |  | (2) Fit a reset buton to the main control panel | 17 | 7
 |  |  |  | (2) Fit a visual indicator when the machine can move automatically | 17 | 7
 |  |  |  | (2) Fit a buzzer to sound for 3s before automatic movement | 17 | 7
 |  |  |  | Fit a fixed guard along the side of the walkway to prevent reach over into the crush hazards ⫺ 1800mm high ⫹ 30[NAME] mesh | 17 | 7
 | Electrocution hazard in the open control panel |  |  | Secure the control cabinet in a way that requires a unique tool to open (electricians key can be used so long as no operators have access to one) | 22 | 16
PCS 3800 | Transmission hazards |  | M | Fit fixed guarding over the  rack and pinion on both sides of the bridge | 18 | 14
 | Pneumatic hazards |  | Main | Replace sharkbite fittings as part of PMs | 15 | 14 |  | 500
 | [NAME] hazards |  | Main | See [NAME] hazard controls | 18 | 14
 | Moderate impact to body/arms as the bridge & carriage transverses automatically during normal operator and troubleshooting |  | FS | Modify the E-STOP lanyards to fully suround the bridge and fit a spring to the non-actuator end to allow activation in all directions. Ensure the reset of the lanyard requries the operator to have direct visual contact along the lanyard path before resetting, sequencial resets may be requried if the lanyard extends around a corner | 12 | 7 |  | 3000
 |  |  | FS | Fit a reset buton to the main control panel | 12 | 7 |  | 500
 |  |  | FS | Fit a visual indicator when the machine can move automatically | 12 | 7 |  | 500
 |  |  | FS | Fit a buzzer to sound for 3s before automatic movement | 12 | 7 |  | 500
KOIKE SANSO-KOGYO 1 | Transmission hazards |  | M | Fit roller guards over the guide rollers and drive sprocket | 21 | 14 |  | 1000
 | Pneumatic hazards |  | Main | Replace sharkbite fittings as part of PMs | 15 | 14 |  | 500
 | [NAME] hazards |  | Main | See [NAME] hazard controls | 18 | -
 | Moderate impact to body/arms and crush to hands/arms as the carriage transverses automatically during normal operator and troubleshooting |  |  | Modify the E-STOP lanyards to fully suround the bridge and fit a spring to the non-actuator end to allow activation in all directions. Ensure the reset of the lanyard requries the operator to have direct visual contact along the lanyard path before resetting, sequencial resets may be requried if the lanyard extends around a corner | 17 | 7
 |  |  |  | Fit a reset buton to the main control panel | 17 | 7
 |  |  |  | Fit a visual indicator when the machine can move automatically | 17 | 7
 |  |  |  | Fit a buzzer to sound for 3s before automatic movement | 17 | 7
 |  |  |  | Fit a fixed guard along the side of the walkway to prevent reach over into the crush hazards ⫺ 1800mm high ⫹ 30[NAME] mesh | 17 | 7
 | Electrocution hazard in the open control panel |  |  | Secure the control cabinet in a way that requires a unique tool to open (electricians key can be used so long as no operators have access to one) | 22 | 16
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