Risk assessment

Machine safety as a manufacturer obligation

As a machine manufacturer on the one hand, your core remit involves developing highly modern machines and production systems.

As a machine operator on the other, you want to protect your staff from hazards posed by machinery.

Many steps intended to ensure the safe operation of systems later down the line, specified by legislative bodies, must be considered along the way, from conception to commissioning.

What you are required to do to ensure risk-free and safe operation by users is set down in law. Such laws are underpinned by standards.

Through our holistic approach, we bridge the gap between CE marking and occupational safety and health. All hazards that you could expect from a machine are duly considered as early as risk assessment.

A quick glance at accident statistics provides some hard-hitting facts: It’s not standard uninterrupted operation that’s the number 1 cause of accidents. Most accidents happen in fact during maintenance, repair and cleaning operations.

We bring no shortage of expertise to the topic and propose viable solutions. You really can forget about risk when it comes to your product.

Machinery risk assessment

The performance of a risk assessment for machines has been legally mandated since 1995 according to the EC machinery directive. A detailed risk assessment is the sole means of verifying a machine’s actual compliance with the requirements of the EC directive. The new machinery directive (MRL 2006/42/EC) has been in force since 29 December 2009. The requirements governing a risk assessment are increased further in DIN EN ISO 12100:2010. The hazards list, for instance, must now be categorised by life phases rather than hazard (EN ISO 12100 section 5.4).

Companies are often lacking standardised procedures for risk assessment. We would be happy to assist you in creating legally compliant risk assessments for machines according to the machinery directive and rigorous terminology for your technical documentation.

With the aid of EN ISO 12100:2010, we identify danger areas, determine expected risk and illustrate options for risk minimisation.

[Information on our risk assessment webinar series]

Performance Level calculation

Standard EN ISO 13849-1 describes the procedure for quantifying hazards and for determining the Performance Level (PLr) for safety functions. The second part of standard EN ISO 13849 specifies how the Performance Level required in the risk assessment is calculated and validated for each technical regulation measure.

Finding the proper protective equipment for each application, inspecting component documentation and filtering out necessary variables is time consuming and costly despite the existing free-of-charge SISTEMA software from the Institute for Occupational Safety and Health (IFA). Trained personnel are therefore required to ensure proper use of the software.

Going on to integrate these parameters in machine regulation in due consideration of category and performance level is complicated and dependent on the necessary stop category.

We’d be happy to provide advice from component selection through to circuit diagram creation for your pneumatic, hydraulic and electrical control components and safety functions. Send us your circuit documentation or tell us how many drives (electrical, pneumatic, hydraulic) and safety functions (emergency stop switches, safety light barriers, scanners, step protection mats etc.) you have, and we’ll provide you with a fixed price quotation. Also take a look at the relevant offers in our academy.

[Information on SISTEMA workshop]

[Information on our SISTEMA webinar series]

CE software & Academy


With CE-CON Safety CE software, risk assessment is made easy. Let us guide you step by step through the individual phases of risk assessment.

Operation is simple and intuitive, meaning anyone can start using it after a brief introduction. Please see our Software page for more information on the CE-CON Safety CE solution.

[To CE-CON Safety]


Are you looking for further training opportunities in the risk assessment field?

Then take advantage of our academy training options. You can book a training course, pursue certification or join webinars from the comfort and convenience of your desk.

See our Academy pages for an overview of topics and content information on the individual packages.

[To the academy]

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