Title Page
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Client / Site
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Location
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Date and Time of Inspection
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Machine Name or Description
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Machine Number
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Inspected by
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Description of work to be performed
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List down the name of employees working on machines
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Choose the type of guards
DOCUMENTATION
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The machine has been risk assessed previously by a competent person and identified corrective actions or recommendations have been completed / closed out?
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A Standard Operating Procedure (SOP) is available for the machine, the SOP includes the safety hazards and warnings, and the safety procedures, and a copy is available for the operators in proximity to the machine?
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Training records are available for all operators in a location easily accessible and unlikely to be discarded or lost (particularly if a supervisor/manager leaves the organisation)?
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Is the machine manual available at the machine for operators to refer to?
PRE-OPERATION CHECKS
MACHINE GUARDS
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Are all machine guards in good condition?
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Do machine guards prevent workers hands, arms, and other body parts from making contact with dangerous moving parts of machine?
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Are workers able to reach through the guards to the moving parts? (refer to AS/NZ.4024 reach charts)
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Are workers able to reach over, around, or under guards to the moving parts? (refer to AS/NZ.4024 reach charts. Note gap under fences or guards at floor level should be max 180 mm).
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Are all machine guards firmly secured and not easily removed?
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Do machine guards ensure that no objects fall into the moving parts?
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Do machine guards permit safe, comfortable, and relatively easy operation of the machine?
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Are all pulleys and belts on working level properly guarded?
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Are all moving chains and gears properly guarded?
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Are all fan blades protected with a guard with opening not larger than the standard size?
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Can the machine be oiled by the operator without removing the machine guards? (does not include full maintenance or servicing requirements - this just refers to the operator actions).
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The operator can make adjustments to the machine whilst running without being exposed to moving parts or energised equipment?
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Does the machinery automatically shut down when machine guard is removed?
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Do machine guards prevent operators to access machinery while in operation?
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Do machine guards protect against hazards to the rear and sides of machinery?
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Is warning sign placed around the machine? (refer to pinch points, noise, dust, falls, slips, and other health hazards)
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Do the guards at the time the machine is set-up protect the operator from interaction close to moving parts of the machine?
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Do the guards protect the worker if samples have to be taken during operation?
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Do the guards protect the operator when there is a machine jam-up, where product has to be removed?
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Have light-curtains been checked as fully functional within the past month by a competent person?
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Have presence sensing devices been checked as fully functional within the past 6-months by a competent person? (Refers to light curtains, pressure sensing pads, pressure sensing bumpers, laser scanners, radar detectors, AI camera detectors,
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There are sufficient emergency stops (AS/NZ.4024 requires an E-stop at every 'operator station', at least one on a conveyor (and additional required every 30-metres along the conveyor)?
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Pullcord emergency stops are placed in correct proximity to the hazardous area? (refer to AS.4024 - if the nip point is below 1500 mm height - the pullcord to be above that and within reach; if the nip point is above 1500 mm height - the pullcord to be below and within reach).
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Have Emergency Stops (push button and pullcord devices) have been checked as fully functional by a competent person within the past 6-months? (requires a proper step-by-step check to be completed)
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Is the operator protected from any pressurised system if it fails? (refers to hydraulic, pneumatic, hazardous substances systems (e.g. nitrogen / oxygen)
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Electrical cabinets or connections are secured (preferably by a lock) to prevent the operator accessing them, and only a competent person can access them (preferably only an electrical engineer/electrician)?
TRAINING
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Are all operators trained to the SOP and deemed competent?
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Does the SOP include the steps to check the safeguards (interlocks, light curtains, emergency stops)?
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Are all operators trained on how machine guards work?
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Do operators have the necessary education and training in how to use the guards?
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Do operators know the procedure when guards are damaged, missing or inadequate?
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Are all operators trained on how and under what circumstances guards can be removed?
PEOPLE
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Are all employees wearing appropriate PPE?
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Do employees follow safe handling instruction using machineries?
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Are all employees aware of emergency procedures in case of an accident involving machinery?
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Is adequate supervision provided to ensure that employees are following safe machine operating procedures?
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Do operators conduct a weekly emergency stop check (i.e. activate the E-stop and ensure the machine deactivates)?
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Do operators conduct a weekly check that any safeguards are operating correctly? (i.e. activate the device and ensure the machine stops - refers to light curtains, pressure bads/bumpers, laser scanners, radar detectors, AI camera systems)
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Maintenance & service personnel are trained on the Isolation-LOTO procedures and signed off as 'competent', by a competent assessor? (note: this 'assessor' can be an experienced, trained, competent operator, or manager)
POST-OPERATION
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Are all machine guards in good condition?
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Is lock-out tag placed when removing machine guard?
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Are all machine updates were escalated to a supervisor?
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Are all incidents reported to a supervisor?
MAINTENANCE
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Maintenance and servicing is conducted using an Isolation-LOTO system?
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Isolation-LOTO procedures are written and available for the specific machine?
COMPLETION
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Observation or recommendations
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Overall assessment
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Inspector's Name and Signature
Sign-off
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Signature of person completing the inspection
