Safe Use of Machinery

When buying new machinery in Great Britain, the equipment must:

• Be either UKCA or CE marked. 
• Be supplied with a declaration of conformity. 
• Have instructions regarding its use in English. 

Employers need to look at how they want employees to approach their use of machinery, which makes conducting risk assessments so important. As a part of the risk assessment process, employers should look at the hazards that may arise specifically because a machine is being maintained.

Risk of Injury

Moving parts of machinery must be guarded so that employees are not:

• Struck by any moving parts or ejected materials.
• Drawn into a machine (trapped between rollers, belts or pulleys).
• Cut by or possibly suffering an amputation due to a sharp edge.
• Stabbed by sharp pointed parts.
• Given a burn or abrasion due to moving rough surfaces.
• Crushed between parts coming together, or being pushed up against and crushed by a fixed part of the machine or a wall.
• Injured by two parts passing each other and providing a shearing risk (amputation).
• Scalded by steam or hot water.
• Burned by direct skin contact with frozen equipment.
• Electrocuted (burned or shocked).

These injuries are more likely to occur if:

• The machine becomes unreliable (develops a fault).
• Machine users have a lack of experience or training provision.

Risk Assessment

Prior to first use, machinery should be risk assessed (what might occur and how). The machine should be complete with all its parts, have all guards fitted, and be free from defects. All guards mean: the physical guards, interlocking guards, two-handed controls, light beam guards, or even pressure-sensitive mats.

The law requires a supplier to provide the right safeguards for the machinery and to inform the buyer of any residual risks that could not be designed out of the machine’s use. This then enables the buyer and the users to be aware of the risks and manage them by other means.

If there are any badly designed safeguards, it is important that they are identified as soon as possible. If they cause inconvenience or are easily overridden, then the employees may stop using them / override them, and in doing so, risk injuring themselves or breaking the law. It is important that these are detected, the reasons determined, and that appropriate action is taken to manage the issue.

The risk assessment should aid in creating safe working procedures which manage the hazards and risks. These procedures need to be included in the training provided to the relevant workforce. 

We have a specific template designed to guide the employer through the assessment process where machinery is concerned. This can be found on our H&S Client Portal, or please feel free to contact us for assistance. 

Control Measures

There is a hierarchy with regard to guards in use on machinery:

• Use fixed guards – secured with screws/nuts/bolts, thereby enclosing the dangerous / moving part(s). Plastic tends to be easily damaged, and if using a mesh type, ensure the holes are small enough to restrict access to fingers.
• Where a fixed guard is not practical, an interlocking type of guard might be, as it usually cannot be removed whilst the machine is still operating or moving.
• Other guarding which trips the machine to ‘off’, such as light beams, pressure sensors, or automatic guards.
• Use of jigs, holders or push sticks where a guard cannot be used.
• Provision of information, instruction and training, with supervision provided until able to work independently.
• Provision of PPE.

Where controlled by other means (programmable electronic systems), ensure the programming is conducted by a competent person. Also:

• Ensure all operating controls are clearly marked with what they do, e.g. start/stop.
• Ensure all “emergency stop” buttons are within easy reach of the operator and are obviously marked.
• Do not let unauthorised or untrained people use machinery.
• Ensure all supervisors are trained and authorised to use the machines they are supervising the use of.
• Ensure all work areas around machinery are kept clean and tidy, free from obstructions and slip/trip hazards, and are kept well lit.

Maintenance

Unsafe maintenance has caused many fatalities and serious injuries, either during maintenance itself, or to those using the badly or wrongly maintained/repaired equipment.

It is advisable to follow a scheduled maintenance plan for machinery, not only to facilitate proper planning and allow for a reporting procedure for any issues noticed, but also to minimise the likelihood of unplanned repairs caused by breakdowns (although these can always still occur). 

Even with a proactive schedule, maintenance is still classed as a non-routine task and may expose those conducting the maintenance to risk. 

PUWER (the Provision and Use of Work Equipment Regulations) requires:

• All work equipment is to be maintained in an efficient state, in efficient order and in good repair. 
• Where any machinery has a maintenance log, the log is to be kept up to date. 
• Maintenance operations on work equipment must be and is carried out safely. 

Maintenance should only be carried out by competent people who have been provided with sufficient information, instruction and training (PUWER Regs 8 and 9).

A contractor conducting maintenance should be able to produce a risk assessment which demonstrates the activity they will be conducting. If the maintenance is being conducted in-house, then a risk assessment of the task/activity must be produced. The assessment should also determine if there are any risks that are specific to the maintenance regimen, e.g. running without guards or with interlocks disabled.

Maintenance is best practice, regardless of regulation, because it can determine if critical features of the equipment need replacement, and where deterioration would cause or could exacerbate a risk of harm. 

Training

We can provide both Risk Assessment and PUWER Awareness training if your business needs further support on the matters raised in this newsletter. Please click here to see our H&S training brochure for more details. 

To avoid accidents, causing harm and facing prosecution,  

 ensure your business complies with health and safety law in 2025, by

• Conducting risk assessments as and when required (prior to undertaking activities). 
• Providing training regarding the risks involved and how to manage them.
• Supervising risk management, as necessary, until competence is demonstrated.
• Formally reviewing risk assessments and associated safe systems of work regularly.
• Updating training provided (toolbox talks, in-house or external formal training).
• Keeping/updating records of all the above processes.

Need help with a Health and Safety matter? Please do not hesitate to contact us.