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⚙️ Machinery risk assessment

Build a structured machinery risk assessment to ISO 12100: set the machine limits, pick hazards from the ISO 12100 library, score each with Severity × Frequency × Probability, apply the 3-step risk-reduction method with a residual re-score, derive the required Performance Level (PLr a–e) for each safety function from the ISO 13849-1 Annex A risk graph, run a PUWER check and an EU Machinery Regulation 2023/1230 (from January 2027) readiness check. Exports to Word.

Machine identification

Machine / equipment

Manufacturer / model

Assessor

Site / location

ISO 12100 clause 5 — determination of limits

Define the machine's limits before identifying hazards — this scopes the assessment.

Use limits (intended use + reasonably foreseeable misuse, operating modes, skill level)

Space limits (range of movement, operator positions, interface with services)

Time limits (foreseeable service life, maintenance / tool-change intervals)

Other limits (environment, cleanliness, housekeeping, properties of material processed)

Task / phase & hazard identification (ISO 12100 type)

Task / life-cycle phase being assessed

Tick the hazards present for this task. They feed the risk register below.

Risk register — score, reduce, residual & required PL

For each hazard: score the initial risk (S×F×P), apply the 3-step risk-reduction method, re-score the residual risk, and read off the required Performance Level (PLr) from the ISO 13849-1 Annex A risk graph. PLr is the REQUIRED Performance Level for the safety function — not the achieved PL. Verifying that your control system reaches it (PL / category / MTTFd / DC / CCF) is a separate step, e.g. with SISTEMA.

No hazards yet — pick hazards above and add them to the register.

PUWER 1998 — work-equipment check (GB)

For equipment used at work in Great Britain. Mark each as OK / Action / N/A.

EU Machinery Regulation (EU) 2023/1230 — readiness

Applies from 20 January 2027, replacing the Machinery Directive 2006/42/EC. Mark each as Ready / Gap / N/A.

⚠️ This tool helps structure a machinery risk assessment to the methodology of ISO 12100 and the risk-graph of ISO 13849-1 Annex A — it is not legal advice and not a substitute for the standards themselves. The S/F/P risk graph is the informative Annex A approach and gives an indicative required Performance Level (PLr); other methods (e.g. IEC 62061 SIL) exist. This tool returns the REQUIRED PL only — it does not verify the achieved PL of your safety-related control system (use SISTEMA or equivalent). Confirm wording, parameters and dates against the current official texts (ISO 12100:2010, ISO 13849-1:2023, PUWER 1998, Regulation (EU) 2023/1230) and have a competent person review the result before relying on it.