8 tips for improving machinery safety

Implementing effective machinery safety measures is crucial to protecting employees and the general public, helping to prevent incidents, injuries and costly disruptions. In this article, we explore eight essential tips for improving machinery safety with actionable steps you can adopt within your organisation.

Tip 1: Complete pre start inspections

Before starting any machine, operators should perform a detailed pre start check to ensure all components are safe and functioning correctly. This inspection will allow for any potential issues to be identified before the machine is operated, reducing the potential for incidents to occur and the need for costly repairs.

Tips to improve your machinery pre start inspections:

• Use standardised checklists
• Provide operators with training to recognise faults and hazards
• Promptly address any issues identified during the pre start inspection

Tip 2: Conduct regular risk assessments

Regular risk assessments are critical for maintaining machinery safety, as they help to identify hazards, determine the level of risk they pose and evaluate the effectiveness of existing control measures. Failing to complete risk assessments regularly could degrade the safety of your machine, increasing the risk of incidents occurring and people being seriously injured or killed.

Tips for improving machinery risk assessments:

• Schedule risk assessments at regular intervals
• Document findings to create historical records for your machine
• Ensure the assessor has extensive knowledge of the machine and a thorough understanding of legal obligations relating to machinery safety

Tip 3: Control hazards promptly and effectively

When a machinery hazard is identified, it is vital to control it effectively and promptly, as delaying corrective actions can lead to an increased risk of an incident occurring. Having a proactive approach to hazard control helps to ensure potential risks are mitigated before they can cause harm.

Tips for promptly and effectively controlling machinery hazards:

• Develop a hazard control plan that outlines procedures for addressing identified risks
• Prioritise hazard control based on the likelihood of an incident occurring and the severity of the potential consequence
• Use the hierarchy of control to determine the most effective control measure and implement promptly

Tip 4: Keep up to date with requirements

Legislation, regulations, standards and codes of practice related to machinery safety are continually evolving. Staying informed about the latest requirements is essential for both compliance and safety. Regularly review legislation and update your safety protocols to align with current regulations when required.

Tips for keeping up with requirements:

• Subscribe to industry newsletters and regulatory updates
• Participate in professional organisations and training programs
• Conduct periodic reviews of your safety procedures to ensure compliance

Tip 5: Systemise operator competency processes

Ensuring machinery operators are adequately trained and competent can be a challenge, especially in large organisations. Implementing a systematic approach to training and competency assessment can help to ensure operators are receiving the education they need and processes are consistent.

Tips for systemising operator competency:

• Develop a comprehensive training program for operators
• Conduct regular competency assessments to ensure ongoing proficiency
• Keep detailed records of training assessment and outcomes

Tip 6: Continually monitor hazards

Continuous monitoring of hazards is essential for maintaining a safe work environment around machinery. Implement an ongoing monitoring program that allows for quick detection of potential risks to machinery safety, enabling prompt corrective actions.

Tips for continually monitoring machinery hazards:

• Implement a program or schedule for ongoing monitoring of machinery hazards
• Evaluate the effectiveness of previously implemented control measures to determine whether they need upgrading or renewing
• Train staff to identify trends and emerging risks to machinery safety and respond effectively

Tip 7: Create a document audit trail

Maintaining a document audit trail is crucial for tracking machinery safety measures and ensuring accountability. Detailed records of pre start checks, risk assessments, corrective actions and operator training provide valuable insights into the safety and compliance of your machinery fleet, ensuring you are ready for audit at a moment’s notice.

Tips for creating a document audit trail:

• Develop a robust documentation system for all safety-related activity
• Ensure documents are easily accessible and regularly updated
• Conduct periodic audits to verify the accuracy and completeness of records

Tip 8: Go digital

Leveraging digital tools and technologies can significantly enhance machinery safety. Digital solutions help to streamline safety processes, improve data accuracy and facilitate real-time communication and monitoring, boosting machinery safety in the workplace.

Tips for going digital with machinery safety:

• Implement digital inspection and maintenance management systems
• Use software solutions for real-time reporting and ongoing communication of safety information
• Roll out digital solutions across the entire organisation to facilitate consistency

Want help improving your machinery safety?

You’ve come to the right place! Ideagen Plant Assessor has a suite of solutions to boost your machinery safety and compliance including free digital pre starts, machine-specific risk assessments with built-in legislative knowledge, maintenance and service scheduling and real-time reporting dashboards. For more information, simply contact us on 1300 728 852 or email us at info@assessor.com.au.

Disclaimer: This information is intended to provide general information on the subject matter. This is not intended as legal or expert advice for your specific situation. You should seek professional advice before acting or relying on the content of this information.

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About the Author

Matthew Turner is Managing Director of Ideagen Plant Assessor. Matt has been a part of Ideagen Plant Assessor since 2008, having gained a deep understanding of workplace health and safety management and behavioural safety management through his extensive experience in the industrial, manufacturing and distribution industries. Read More.