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Risk Assessment in Robotic Workcells

Your robotic systems may improve operational efficiency, but they also present potential risks to your equipment and supplies, and, more importantly, to your employees and facility visitors. One way to reduce injury risks is to perform period risk assessments, which provide a standardized, objective approach to determining the unique hazards in your facility and what your safety officers can do to mitigate them.

When Risk Assessments Should Occur

Many supervisors assume that the original equipment manufacturer is responsible for assessing risk, but this duty actually falls to the company or manufacturer that purchases and installs the equipment.

As a general rule of thumb, risk assessments should be proactive, never reactive, after an accident has already occurred.

Risk assessments should ideally occur:

  • As soon as you place a new machine or robot within a workcell.
  • Whenever you change a process in your facility.
  • The moment you identify a new hazard on the factory floor.

Performing the Assessment

1. Identify Potential Hazards & Determine Safety Goals

Your first step is to identify potential dangers associated with your robotic equipment and any conditions or circumstances that contribute to the risk.

Each worksite has specific hazards that require risk assessment. Consult standards, codes, and regulations for guidance on the risks in your industry to help you identify the most worrisome ones.

Examples of hazards that could injure people, harm the environment, or damage equipment include:

  • Chemical releases, such as toxic fumes spreading throughout the environment and leaks or spills on the manufacturing floor.
  • Radiation from sources such as microwaves, X-rays, and lasers.
  • Electrical problems, ranging from potential fires to electric arcs and shocks.
  • Mechanical issues like entrapment (a person gets stuck in equipment), pinch points (harming appendages), and equipment collisions.
  • Thermal dangers from overheated equipment, burns, or actual explosions.
  • Human error caused by fatigue, distraction, or lack of training.

Tip: Make sure you speak with as many people as possible who interact with this machinery to get a complete picture of what could go wrong. We also recommend consulting with a certified safety representative who can provide more guidance on risk identification.

2. Prioritize Found Hazards

Next, prioritize the hazards list you’ve generated to rank each hazard’s severity and likelihood of occurrence. For example, what’s the likelihood that an employee might be shocked or burned when maneuvering near a robotic workcell? Or, what might happen if a worker is distracted in the presence of a robot?

We recommend creating a checklist and using event tree analysis or failure mode and effect analysis to help you prioritize which risks to address first.

Your plant is unique. Determine which hazards have the most significant consequences for your employees, visitors, and surrounding equipment.

3. Evaluate Your Findings

Next, you’ll need to compare how risky each potential hazard is, according to the acceptable risk criteria standards outlined in your company’s procedures and OSHA standards.

Doing so will ensure you know what government investigators expect in case a dangerous situation unfolds in your workplace.

4. Take Steps to Reduce Risks

Generally, risk reduction and mitigation steps will include:

  • Picking the most suitable type of robotic equipment for your use case scenarios.
  • Installing safeguards, such as sensors and machine guards.
  • Emphasizing safety protocols during worker onboarding and ongoing employee education and instruction.
  • Verifying you have placed sufficient labels, signs, and warnings to follow when working with or near robotic workcells.

What’s important to remember here is that your mitigation approach will vary based on the risks you find and prioritize in your workplace. We recommend working with a consultant to determine the best approach for your workplace, which could be total elimination, installing automated controls, or enhancing existing workflow, or improving existing training procedures.

Get Tailor-Made Solutions to Reduce Your Site Risks

Robo-Fence® Machine Guards

In many cases, machine guarding is one of the best ways to mitigate many of the risks of robotic workcells. At ROBO FENCE®, we understand that every manufacturer is different. That’s why we provide custom-tailored solutions. When you work with us, you can expect on-site consultations and exceptional collaboration and support throughout the entire design process.

Contact ROBO FENCE® today to get started.

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