Machinery Risk Assessments
Neuguard provides structured, legislative and standards-based machinery risk assessments to identify hazards, evaluate risks, and define appropriate control measures, supporting CE/UKCA compliance, technical documentation, and safe machinery design, operation, and modification.
Design Risk Assessments in accordance with EN ISO 12100
At Neuguard, we develop machinery Design Risk Assessments that provide a clear, structured and standards-based record of how machinery risks have been identified, evaluated and reduced during the design process.
A Design Risk Assessment is a key part of the CE/UKCA compliance process and forms an essential element of the machinery technical file. It demonstrates how foreseeable hazards have been considered throughout the machine lifecycle, and how suitable protective measures have been specified in accordance with the principles of EN ISO 12100.
Our approach is practical, detailed and design-focused. We work with machine builders, integrators and end users to review the machine concept, layout, intended use, operating modes and foreseeable misuse, before identifying hazards associated with each stage of the machinery lifecycle. This includes transport, assembly, installation, commissioning, normal operation, setting, cleaning, maintenance, fault-finding, decommissioning and dismantling.
For each identified hazard, we evaluate the level of risk and define appropriate risk reduction measures using the hierarchy of control set out in EN ISO 12100. This means prioritising inherently safe design measures wherever possible, followed by safeguarding and complementary protective measures, and finally information for use such as warnings, signage and instructions.
A typical Neuguard Design Risk Assessment includes:
- Machine layout and description
- Defined machine limits, operating modes and lifecycle phases
- Relevant assumptions and risk assessment criteria
- Applicable standards and legislative requirements
- Identification and evaluation of machinery hazards
- Annotated pages for specific hazardous areas or functions
- Recommended design-stage control measures
- Assessment of residual risks
- Safety signage and warning requirements
- Evaluation of applicable Essential Health and Safety Requirements
- Consideration of safety-related control functions in accordance with EN ISO 13849-1
Where safety-related control systems are required, we can also support the definition of safety functions, Performance Level requirements and validation expectations in accordance with EN ISO 13849-1 and EN ISO 13849-2.
Our objective is to produce a Design Risk Assessment that is not just a compliance document, but a useful engineering tool. The output gives project teams a clear basis for design decisions, corrective actions, technical documentation and final conformity assessment.
Site Based Risk Assessment
Neuguard’s site-based machinery risk assessments are designed to provide a practical, focused evaluation of machinery in its existing operating environment.
Our approach is based on a “risk assessment by exception” methodology. This means we do not produce lengthy generic assessments covering every possible theoretical hazard. Instead, we identify existing hazards, deficiencies and areas of non-compliance observed during the site inspection, then provide clear and practical corrective actions to reduce risk.
Each corrective action is developed with careful consideration of what is reasonably practicable and achievable within the client’s operational environment. We consider the severity of the hazard, likelihood of exposure, existing safeguards, production constraints, available technology and the practicality of implementing additional controls.
Using ALARP principles, our assessments aim to help clients reduce machinery risks as low as reasonably practicable without recommending unnecessary, disproportionate or unrealistic measures. The result is a clear, usable report that supports legal compliance, prioritised action planning and practical improvement of machinery safety.
Our Scoring Methods
Neuguard can apply a range of recognised risk assessment scoring methods to suit the project, machinery type and client’s internal procedures.
Our preferred approach is the Hazard Rating Number system, as it provides a clear, repeatable and numerical basis for evaluating risk, prioritising actions and demonstrating risk reduction.
However, where clients have established scoring matrices or corporate risk ranking methods, we adapt our approach to align with their existing systems. Our consultants are trained and competent in the use of qualitative, semi-quantitative and numerical scoring methods, allowing us to produce assessments that are both technically robust and practical to use.
Practical, Compliance-Focused Reporting
Our risk assessment reports are designed to be clear, practical and easy to act on. We avoid unnecessary complexity and focus on identifying the hazards that matter, explaining the compliance issue, and providing proportionate corrective actions that can be realistically implemented.
Each report is structured to support decision-making, action planning and evidence of compliance. Whether the assessment is completed for CE/UKCA marking, PUWER compliance, design review or machinery modification, our aim is to provide a technically robust document that helps clients understand their risks and take clear steps towards reducing them.
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