Risk Assesment

RISK ESTIMATION
HAZARDS IDENTIFICATION RISK ESTIMATION

Machine Method \ Tool

MAGNA POWER TRAIN

Customer Analyst
(60003522)

Vacuum Pump Assembly

Station Name & Performace Testing Current Version
Line 3

Date 27/1/2015

Hazardous
Task/Orientation Hazard Hazardous Event Risk Estimation Risk E
Situation
Sl.No Hazard Zone EN ISO 14121-1 :2007, ( EN ISO 14121-1 :2007, (EN ISO 14121-1 :2007, (Before Risk (Af
(EN ISO 14121-1 :2007,
Table A.3) Table A.1) Table A.4) Reduction) Re
Table A.3)

Frequency and/ or Possibility of Required

Seviority of
OP10 Exposure time to the avaoiding the Performance Level S F
Injury((S)
hazard(F) Hazard(P) PLr

Unexpected /
Manual Loading of the Press
1 .- Unintended 1 2 1 b 1 2
component Injury (Manual Press)
start-up
Oil restrictor, ball
assembly and flow test Unintended Acess of Hazrd
Area(Oil restrictor pressing Work under powered
Contact with Moving
2 cylinders) during Auto cycle Electrical actuators 1 2 2 c 1 2
Injury Parts
running
And during Maintanance

OP20

Work under powered Unexpected /

Manual Loading of the
1 Injury Electrical actuators Unintended 1 2 2 c 1 2
component
start-up

Tightening, flow test &

oiling inlet connector Unintended Acess of Hazrd
Area( Screwing, Leak test, Work under powered
Contact with Moving
2 Oiling cylinders) during Auto Injury Electrical actuators 1 2 2 c 1 2
Parts
cycle running
And during Maintanance

OP30

Work under powered Unexpected /

Manual Loading of the
1 Injury Electrical actuators, Unintended 1 2 2 c 1 2
component
start-up

Second Inlet connector:

Pressing, tightening &
testing, oiling
 Second Inlet connector:
Pressing, tightening & Unintended Acess of Hazrd
testing, oiling Area(Inlet connector
Work under powered
Screwing,Pressing, Testing Contact with Moving
2 Injury Electrical actuators 1 2 2 c 1 2
cylinders) during Auto cycle Parts
running
And during Maintanance

OP40

Unexpected /
Manual Loading of the Press
1 .- Unintended 1 2 1 b 1 2
component Injury (Manual Press)
start-up
Rotor coupling assembly
in housing Unintended Acess of Hazrd
Area(clamping Work under powered
Contact with Moving
2 cylinder)during Auto cycle Injury Electrical actuators, 1 2 2 c
Parts
running
And during Maintanance
OP50,60
Work under powered Unexpected /
Manual Loading of the
1 Injury Electrical actuators, Unintended 1 2 2 c 1 2
component
Vane cap, cover seal start-up
assembly, oiling & Unintended Acess of Hazrd
tightening Work under powered
Area(Pallet Lifting cylinders) Contact with Moving
2 Injury Electrical actuators 1 2 2 c 1 2
during Auto cycle running Parts
And during Maintanance
 OP70 & 80
Work under powered Unexpected /
Manual Loading of the
1 Injury Electrical actuators Unintended 1 2 2 c 1 2
component
start-up

Leak testing. Functional Unintended Acess of Hazrd

test, Area(Clamping,Dot Marking,
Work under powered
Inlet connector locking Contact with Moving
2 Injury Electrical actuators 1 2 2 c 1 2
cylinders) during Auto cycle Parts
running
And during Maintanance

OP90
Work under powered Unexpected /
Manual Loading of the
1 Injury Electrical actuators Unintended 1 2 2 c 1 2
component
Protection cap , Sealing start-up
assembly & Labelling Unintended Acess of Hazrd
station, Area( Seal checking, Work under powered
Contact with Moving
2 Labeling cylinders) during Injury Electrical actuators 1 2 1 b 1 2
Parts
Auto cycle running
And during Maintanance
OP05

Work under powered Unexpected /

Manual Loading of the
1 Injury Electrical actuators, Unintended 1 2 2 c 1 2
component
start-up

Unintended Acess of Hazrd

Area(Inlet connector
Work under powered
First Inlet connector: Screwing,Pressing, Testing Contact with Moving
2 Injury Electrical actuators 1 2 2 c 1 2
Pressing, tightening & cylinders) during Auto cycle Parts
Testing, oiling running
And during Maintanance

Unintended Acess of Hazrd

Area(Stamping, Oiling Work under powered
Contact with Moving
3 cylinders) during Auto cycle Injury Electrical actuators, 1 2 2 c 1 2
Parts
running
And during Maintanance

Conclusion: We have done further Analyisis and found that all

the control system meets PLr required(Based on the
category, Diagnostic coverage and MTTFd of the
channles
Assesment
RISK ESTIMATION RISK REDUCTION

Risk Estimation
(After Risk Risk reduction
Reduction)

Required
P Performance Level
PLr

No risk(bcecause only manual press is there and there is no

1 b
criticality) . Only proper SOP. Label has been provided.

Guard is provided. Guards to avoid access to the machine parts

1 a which need not be accessed except during part replacement/Major
repair.

Light curtain is provided to monitor the interruption.. Light curtain

1 b
to indicate Operator intervention in the middle and process stops

Light curtain is provided to monitor the interruption.. Light curtain

1 b
to indicate Operator intervention in the middle and process stops

Light curtain is provided to monitor the interruption.. Light curtain

1 b
to indicate Operator intervention in the middle and process stops
 Light curtain is provided to monitor the interruption.. Light curtain
1 b
to indicate Operator intervention in the middle and process stops

No risk(bcecause only manual press is there and there is no

1 b
criticality) . Only proper SOP. Label has been provided.

Hazardous Load elininated, Provided by cylinder pressure which

eliminate cause of injury

Two hand push buttonis provided to avoid Opeartor intervention in

1 b
the middle of the operation

Two hand push buttonis provided to avoid Opeartor intervention in

1 b
the middle of the operation
 Two hand push buttonis provided to avoid Opeartor intervention in
1 b
the middle of the operation

Two hand push buttonis provided to avoid Opeartor intervention in

1 b
the middle of the operation

Guard and Label is provided. Guards to avoid access to the

1 a machine parts which need not be accessed except during part
replacement/Major repair.

Guard and Label is provided. Guards to avoid access to the

1 a machine parts which need not be accessed except during part
replacement/Major repair.

Light curtain is provided to monitor the interruption.. Light curtain

1 b
to indicate Operator intervention in the middle and process stops

Light curtain is provided to monitor the interruption.. Light curtain

1 b
to indicate Operator intervention in the middle and process stops

Guard is provided. Guards to avoid access to the machine parts

1 a which need not be accessed except during part replacement/Major
repair.