GB/T 16856.1-2008Safety of machinery -- Risk assessment -- Practical guidance and examples of methods (English PDF)

4.1 General

The objectives and scope of the risk assessment should be clearly defined.

The supplier shall carry out the risk assessment of the machine including the machine control system according to GB/T 15706-2012.

Note. Refer to Chapter 1 for the purpose of the proposed risk assessment and/or the user.

4.2 Use the assessment team to conduct risk assessment

4.2.1 General requirements

The composition of the assessment team to carry out risk assessment is usually more thorough and effective. The size of the assessment team varies depending on the following conditions.

A) the selected risk assessment method;

B) the complexity of the machine;

C) the process of using the machine.

The assessment team should be composed of experts with different disciplines of knowledge, experience and expertise. However, the assessment team is too likely to cause it is difficult to maintain consensus or reach a consensus. The composition of the assessment team during the risk assessment process, depending on the specific skills required by the specific issue can change. It is advisable to explicitly implement the project's assessment team because the success of the risk assessment depends on its skills.

The risk estimate should be completed by a team and reached a consensus, and the different team's detailed results for the analysis of the similar situation not necessarily exactly the same. However, it is not always necessary to establish a risk assessment team in practice, since some mechanical hazards have been sufficient Cognition.

Note. By consulting other persons with knowledge and expertise as described in 4.2.2 and examining the risk assessment by another qualified person, the credibility of the risk assessment.

4.2.2 Composition and role of the members of the assessment team

The assessment team should have a group leader, the group leader should ensure that the risk assessment in line with GB/T 15706-2012 Chapter 7 requirements, in the Zoning, all tasks involved in the implementation process and in the preparation of the document are fully responsible and report the assessment results and/or recommendations to the appropriate personnel.

Members of the assessment team should be selected based on the skills and expertise required for risk assessment. The following groups should be included in the assessment team.

A) who can answer questions about mechanical design and functional aspects of technology;

B) personnel with practical experience such as mechanical operation, commissioning, maintenance and repair;

C) persons who understand the history of such mechanical accidents;

D) familiar with the relevant laws and regulations, standards, in particular GB/T 15706 and the specific safety issues associated with the machinery evaluated;

E) Personnel who understand human factors (see GB/T 15706-2012, 5.5.3.4).

4.2.3 Selection of methods and tools

This standard is intended for risk assessment of machinery with very different levels of complexity and potential hazards, for the purpose of conducting risk assessment There are also many instruments and tools (see Chapter 6). When choosing a method or tool to estimate the risk, it is advisable to consider the possible nature of the machinery, the purpose of risk assessment. It is also advisable to consider the risk assessment of the assessment team's skills, experience and preferences for specific methods. Chapter 5 provides the risk the evaluation process selects additional information for each step of the appropriate method and the criteria for the tool.

4.2.4 Sources of risk assessment information

The information required for risk assessment is listed in 5.2 of GB/T 15706-2012. The information may be passed, such as technical drawings, charts, photographs (Including maintenance records and standard operating procedures (SOP)], and other forms of carrier access. If it can be Row, similar machines or designed prototypes are often also useful.

5.1 General

The following sections describe what should be considered at each step of the risk assessment process shown in Figure 1 in GB/T 15706-2012.

5.2 Determination of mechanical limits

Note. The following sections detail some of the requirements of 5.3 in GB/T 15706-2012.

5.2.1 Overview

The purpose of this step is to mechanical properties and physical properties, mechanical completion of the function of the ability to use, can be reasonably expected misuse, machinery Use and maintain the possible environmental conditions, give a clear description.

By checking the function of the machine and working with how to use the machinery to help achieve the purpose and requirements.

5.2.2 Mechanical (machine-based) functions

The machine may be described in terms of mechanical structure and, as in the following modes of operation, depending on the components, mechanisms or functions.

--- power source;

---control;

--- operating mode;

--- feeding;

Movement/movement

Enhance

- to provide stability and/or mobility of the rack or chassis;

---annex.

When the introduction of protection and/or risk reduction measures in the design, they should describe their functions and the interaction with other functions of machinery effect.

Risk Assessment Each functional component should be viewed in turn to ensure proper consideration of various operating modes and all stages of use, Other functional or functional components related to human-machine interaction.

5.2.3 Use of machinery (based on mission)

By considering all the personnel who are scheduled to interact with the machinery in a given environment (eg factory, home), according to the use of the machine and Reasonably foreseen misuse of related tasks to describe the use of machinery.

Note. For a typical and/or general list of mechanical tasks, see Table B.3 in GB/T 15706-2012.

Machinery suppliers and users should communicate with each other, as far as possible, to ensure that all machines that include reasonably misinterpreted, use. Therefore, the following factors should be considered in addition to the operation and maintenance of personnel in the analysis of tasks and work conditions.

A) the availability of information that can be obtained with the machine;

B) the easiest or quickest way to complete the task may differ from those in the guidelines, procedures and instructions;

C) the response of a person to a failure, event or failure when using the machine;

D) Human error.

As long as the designer and/or the manufacturer can properly understand this knowledge, the use of the machine and/or the operation of the various conditions of the test is effective. In these cases, the manufacturer shall consider the intended use of the machine and the reasonable misuse that may be reasonably foreseeable.

5.3 Hazard identification

Note. see GB/T 15706-2012 5.4.

5.3.1 Overview

The purpose of hazard identification is to form a list of dangerous, and/or hazardous events that can describe the state of danger when and how to cause injury to the occasion of the accident. The identification of the relevant hazards can be made from Appendix B of GB/T 15706-2012, this appendix can be used as a general list of hazard checks. Other hazards may be based on the information given in 5.4 of GB/T 15706-2012 Identify.

Refer to criteria related to specific hazards or specific types of mechanical safety, for hazard identification and expected protection and/or risk reduction measures Shi are very useful.

Hazard identification is the most important step in any risk assessment. Only after the danger is identified, it is possible to take action to reduce it Relevant risks (see Chapter 6), unidentified hazards may cause injury. Therefore, as described in 5.5.3 of GB/T 15706-2012 it is essential to ensure that hazard identification is as systematic and comprehensive as possible.

Note 1. 5.3.4 gives an example of a hazard identification tool.

Note 2. Examples of specific hazard-related standards. electrical hazard is GB 5226.1.

Note 3. Examples of specific mechanical safety standards. The standard for robots is ISO 10218; the standards associated with textile machinery are ISO 11111 (all sections Points); the standard associated with industrial vehicles is GB 10827 (all parts).

5.3.2 Hazard identification methods

The most effective method or tool is to ensure that all phases of the mechanical life cycle and all mechanical operations Mode, all functions and those tasks of those methods or tools.

At present, there are many ways to systematically identify hazards. The most commonly used are the following two methods (see Figure 1).

Top-down method, the method to potential consequences (such as cutting, extrusion, hearing loss, see GB/T 15706-2012 in Table B.1 and Table B.2) as a starting point to determine the risk of injury (the identification process is traced back to a dangerous state by a dangerous event, Dating back to danger itself). Each of the checklists is applied to each stage of the mechanical use, each component, each can and/or task. One of the shortcomings of the top-down approach is that the assessment team is overly dependent on a checklist that may not be perfect. A lack of experience of the assessment group may not be able to properly use the method. Therefore, the checklist should not be considered as perfect, but should be encouraged beyond the scope of the list Creative thinking.

Figure 1 top-down and bottom-up approach

From bottom to top, to check all the hazards as a starting point, consider all possible errors in the identified dangerous state (eg, Component failure, human error, mechanical failure or accidental action) and the manner in which it causes injury (see Table B.1 and Table 1 of GB/T 15706-2012 B.2). The bottom-up law is more thorough than the top-down method, but may take too much time.

Note. Figure 1 explains the structure of a hazard identification method, but the flow chart does not define the relationship between a dangerous state, a risk event, and an injury.

5.3.3 Information records

The risk of identification should be recorded with the progress of hazard identification. Any system for recording information should be organized in an appropriate manner, to ensure that the following information is clearly described.

A) Danger and its location (danger zone);

B) the state of danger, the type of person specified (eg maintenance personnel, operator, person) and their execution of exposure to danger Service or activity;

C) the way the damage is caused by a dangerous event or prolonged exposure. Sometimes, at this stage of the risk assessment process, it should also be expected Record the following information.

1) the nature and severity of the specific mechanical damage (consequence) (for example, the downward stroke of the press when adjusting the workpiece) Rather than a general description (eg, extrusion);

2) existing protection and/or risk mitigation measures and their effectiveness.

5.3.4 Examples of Hazard Identification Tools - Use of forms

5.3.4.1 Overview

This article is intended to describe the use of the checklist as defined in B.2 to B.4 of GB/T 15706-2012 as the primary tool for hazard identification (See GB/T 15706-2012, 5.4).

These lists should be used as a starting point for identifying hazards. Therefore, in order to ensure that the risk of identification is more comprehensive, but also to consider other resources (Eg regulations, standards, engineering expertise, etc.).

The method may be based on, for example, a collective study, a comparison with a similar machine, an accident and/or event related to a similar machine Data inspection and other methods to be added.

The more effective and complete the method is, the more detailed the risk assessment (see GB/T 15706-2012 5.2) and the determination of mechanical limitations (See 5.2 and GB/T 15706-2012 5.3) will be the more useful information.

This method applies to any stage of the machine life cycle.

5.3.4.2 Description of tools or methods

Taking into account the mechanical limitations, the first step is to determine the range of systems to be analyzed, such as the various stages of the machine life cycle, Parts and/or functions.

The second step is to determine, in each selected phase, the tasks performed by the person interacting with the machine or near the machine, Device to perform the operation. This step can take the list of tasks specified in Table B.3 of GB/T 15706-2012.

The third step is to check for each hazard or possible hazard state for each task or operation within each particular hazard zone. If the starting point is Potential consequences (damage), this step can be used to implement from top to bottom method; if the starting point is a dangerous source, then use bottom-up law. In this step , We will use Table B.1 and Table B.3 describin...