E FSS5 Attm1 General-Machine-Checklist Rev2 090330 PDF

FSS 5, Attachment 1:
General Machine Safety CHECKLIST

Minimum safety requirements for machines and apparatus within Freudenberg
(powered equipment, machines and systems - not including Industrial Trucks)
Job No.
Issue Date: 2009-03-30 Revision: 02
I. Type of Inspection
Initial Inspection Repeat Inspection
II. Details of the machine

Internal system designation
Designation Type Serial No. Year of Manufacturer/ Location

construction
supplier
1.
2.
3.
III. Scope of the inspection:

All safety related functions and components must satisfy the requirements of the FSS 5 General Machine
Safety Checklist and local relevant standards as a minimum requirement. NOTE: If machines are used in
conjunction with other machines or equipment, a supplementary safety check must be carried out with
reference to the checklist for coordinated machinery and equipment (Attachment 2).
IV. Results of the inspection

The machine/apparatus/system complies with the current FSS 5 checklist.
The machine / system does not meet every requirement of the FSS 5 checklist. However, the
machine / system may be used as the functions concerned are not critical in terms of safety.
The machine/apparatus/system does not comply with the current FSS 5 checklist.
The machine/apparatus/system will be upgraded.
Initial cost estimate: _______________ Date: _______________
Renewed inspection required!
The machine/apparatus/system will be removed from service on __________ at the latest.
Technical and/or organizational measures as laid down in the appendix will be implemented to
ensure safe operation up to this date.
Date of next scheduled inspection: _______________
V. Distribution list
Person responsible for corrective action
and improvements:
Person responsible for documentation,

filing and archiving:
VI. Inspection conducted by:

Mechanical part Electrical part Production Other
Name
Date
Signature
Page: 1 of 11
Inspection Irrelevant OK Not References Remarks
Machine / system designation: OK
1 Documentation / Orderliness
1.1 Does the machine have a rating plate / name plate? (details of the manufacturer,
type, year of construction, etc.)
1.2 Is the documentation available at the machine? Refer to the machinery directive for a
list of the documents that make up
an expedient complete set of
documentation.
1.2.1 Is an up-to-date version of the operating manual available in the native language Provided by the
of the country where the machine is used? manufacturer
1.2.2 Does the operating manual contain information concerning the residual risks Provided by the owner
associated with the machine?
1.2.3 Are documented procedures available for the machine / process?
1.2.4 Does the operating manual contain all of the information on safety that is required
for operation and maintenance? Do they include measures against residual risks?
1.2.5 Has a hazard assessment been carried out in accordance with FSS 10?
1.2.6 Is a electrical circuit diagram available and is it up to date?
1.2.7 Is a hydraulic diagram available and is it up to date?
1.2.8 Is a pneumatic diagram available and is it up to date?
1.3 Does the machine bear the necessary safety and hazard warning signs?
1.4 Is the maximum sound level given in the operating manual and is this less than
80 dB? If the sound level cannot be reduced to less than 80 dB, supplementary
measures must be taken (PPE, enclosure etc.).
1.5 Does the maintenance schedule give details of when safety related parts /
components of the machine are to be inspected and the ways in which they are to
be checked and maintained?
1.6 Does the maintenance plan take the operating conditions into consideration?
(3 shifts etc.)
1.7 For machines used in Europe that were brought into circulation after 1995: Is an
EC declaration of conformity available for the machine / system as a whole?
Page: 2 of 11
2 Intended purpose of machine and equipment

Visual inspection with reference to the instructions issued by the manufacturer
2.1 Is the machine or equipment solely used for the purpose for which it was designed
and built by the manufacturer? (speed, material, tools, etc.)
2.2 Is the machine or equipment solely operated under the ambient conditions
specified by the manufacturer? (temperature, humidity, altitude, etc.)
2.3 Is the machine connected to the energy levels specified by the manufacturer?
(maximum pressure, electrical fuses, voltage, nominal frequency, etc.)
3 Lighting Safe conditions must be achieved in

Visual inspection accordance with local legislation.
3.1 Are the working zones adequately illuminated for the work performed in them?
3.2 Are the maintenance and service areas adequately illuminated for the work
performed in them?
4 Anchorage of the machine(s) / equipment and parts

Visual inspection with reference to the instructions issued by the manufacturer
4.1 Has the machine been anchored / secured in accordance with the manufacturer's
instructions and have the normal loads and stresses, which may be encountered
in operational service, been taken into consideration?
4.2 Have all machine parts, components, guards and safety devices been fitted Also refer to section 9 on
properly and securely? "safety bolts"
5 Alarm facilities
Visual inspection and function test
5.1 Can the operator see into the hazardous zone from the operator's station?
Page: 3 of 11
5.2 If the operator is unable to see into the hazardous zone(s):

has a system been installed that detects the presence of a person in the
hazardous zone, or does the monitoring system issue an acoustic or visual alarm
signal before the machine is started?
5.3 Are the visual warning signals easily seen and can they be distinguished from
other warning signals?
5.4 Are the acoustic warning signals easily heard and can they be distinguished from .
other warning signals?
5.5 Does an employee have sufficient time to leave the hazardous zone prior to start- The escape time must be calculated
up? in such a way as to ensure that the
worker can reach the nearest stop /
emergency stop button safely
6 Command facilities
6.1 Are the command facilities clearly recognizable as such and are their functions
easily distinguishable?
e.g.: - emergency stop impact button
- control panel switches etc.
- master switch
6.2 Are the command facilities unambiguously and durably labeled in the native
language of the country of use?
6.3 Can the command facilities be operated inadvertently?
6.4 If the machine/system can be operated from different operating stations, has a
pre-selection facility been installed for the operating station?
6.5 Are the command facilities fitted outside the hazardous zone(s) and can they be
operated safely?
6.6 Are the control facilities protected against damage?
6.7 Is the emergency stop device easily accessible and is it colored RED against a
YELLOW background?
Page: 4 of 11
7 Control facilities (electrical, pneumatic and hydraulic)

7.1 Starting the machine / system
Function test in accordance with the operating manual
7.1.1 Are the elements required to START the machine / system protected to prevent
them being operated inadvertently?
7.1.2 Is it only possible to control an essential operating state by deliberately operating For example:
the command facilities provided for this purpose? the machine does not start when an
alarm or emergency stop button is
reset!
7.2 Shutting the machine / system down
Function test in accordance with the operating manual
7.2.1 Is there a master switch to turn the complete machine on and off?
7.2.2 Can the master switch be secured to prevent unauthorized or inadvertent
operation?
7.2.3 Are command facilities to deactivate potentially hazardous movements / parts or
the machine as a whole provided at every workplace?
7.2.4 When the system is shut down, does this result in the machine assuming a safe
state?
7.2.5 Is the machine SHUTDOWN command down given precedence over the
command to START the machine?
7.2.6 Are easily accessible and clearly recognizable facilities provided to disconnect the
machine from every single energy source?
7.2.6.1 Is it possible to disconnect the electrical power supply? Refer to FSS 1
7.2.6.2 Is it possible to disconnect the pneumatic energy supply? Refer to FSS 1
7.2.6.3 Is it possible to disconnect the hydraulic energy supply? Refer to FSS 1
7.2.6.4 Is it possible to disconnect the steam energy supply? Refer to FSS 1
7.2.6.5 Is it possible to disconnect all other energy supplies? Refer to FSS 1
7.2.7 After disconnecting a source of energy, do no further hazards exist, e.g.
movements triggered by stored energy or letting go of lifted loads?
Page: 5 of 11
8 Guards and safety devices Refer to EN 954 / ISO EN 13849 /

(electrical, pneumatic and hydraulic) ISO EN 60204
8.1 Have all cables / hoses / pipes been fitted properly and are they protected against
damage?
8.2 Do the safety devices and emergency stop facilities operate reliably? A safety
device failure must lead to the machine coming to a standstill! It must not give rise
to any potentially hazardous movements.
8.3 Are the installed safety functions in accordance with the hazard-specific and risk- Refer to EN ISO 13849-1 /
specific safety level (category / PF-Level / SIL-Level)? IEC 61508
8.4 Have the emergency stop facilities been designed as pushbuttons?
Emergency stop actuating components may also take the form of bars at waist
height, cable-operated switches etc. as and when necessary.
Have the emergency stop facilities been designed as red palm-size pushbuttons
or mushroom-head pushbuttons with a yellow background?
Do the emergency stop facilities enable a local reset?
Have the emergency stop actuating elements been designed as latching
components (it must not be possible to reset by simply removing the load from the
actuating component)?
8.5 Does the emergency stop facility transpose potentially hazardous movements or
processes into a safe state as quickly as possible?
8.6 After an emergency stop or safety stop, can the machine only be restarted by a
command from the operator?
9 Risk of mechanical contact with moving plant components

Visual inspection and function test in accordance with the operating manual
9.1 Are safety devices or safeguards in place that prevent access to hazardous zones
or bring potentially hazardous movements to a standstill before personnel can
reach the hazardous zone?
9.2 Are all guards and safety devices in the right places and are they in good working
order?
9.3 Have the safety devices or guards been designed and built as rugged elements?
Page: 6 of 11
9.4 Do the safety devices or safeguards not give rise to any additional hazards?
9.5 Are all guards and safety devices secured with safety bolts? (safety devices, Purpose of the safety bolts: it must
guards, safety switches, light barriers, etc.) not be possible to remove guards or
safety devices without using special
tools.
9.6 Is sufficient clearance maintained between the safety devices or safeguards and Are all safety clearances in
the hazardous zone? accordance with the requirements of
the EN 294 / OSHA standards with
respect to opening safeguards or
ANSI B 11?
9.7 Do the guards and/or safety mechanisms obstruct the necessary observation of
the processes?
9.7.1 Are there no sharp or uneven edges or protruding components?
9.8 Fixed guards and safety devices Refer to EN 953

9.8.1 Have all fixed guards / safety devices been fitted in their designated places Purpose of the safety bolts: it must
properly, with at least 2 safety bolts? (at least 2 safety bolts are required for each not be possible to remove guards or
fixed guard / safety device) safety devices without using special
tools.
9.8.2 Are safety switches in place, which monitor the fixed safety devices that are
opened more than once a year?
9.9 Moving guards and safety devices Refer to EN 953

9.9.1 Are all moving safety devices monitored by safety facilities (e.g. safety switches), Refer to EN 954 / ISO EN 13849 /
and does the safety monitoring loop take place in the necessary safety category? IEC 61508
9.9.2 Are the safety doors which allow access to moving parts with stopping time
secured by means of interlocking elements?
9.9.3 Have measures been taken to prevent manipulation of the fitted guards and safety
devices?
Page: 7 of 11
9.9.4 Are the edges of powered guards and safety devices protected by safety The maximum force may be limited
shutdown facilities? (safety contact bars) to 150 N as an alternative measure,
but attention must be given to
maintenance.
EN 12978
9.9.5 Have measures been taken to prevent vertically moving safety devices falling?
9.10 Other safeguarding methods Refer to EN 999.

(e.g. light barriers, laser scanners, two-hand triggering facilities, pressure- Positioning protective equipment with
sensitive mats) respect to approach speeds of parts
of the human body.
9.10.1 Have the safety clearance, stopping time and stopping distance been defined?
9.10.2 Is the information concerning safety clearance, stopping time and stopping
distance given on the machine or in the operating manual?
9.10.3 Are the safety clearance, stopping time and stopping distance in accordance with
the manufacturer's specifications and/or EN 999? (measurements)
9.10.4 Does the safety device remain active until the contact gap is less than 4 mm
wide?
9.10.5 Have the guards and safety devices been installed in such a way that it is
impossible for a person to stand behind them?
(maximum clearance less than 75 mm)
9.10.6 If a two-hand triggering facility has been installed, is the permitted interval Refer to EN 574
between pressing the two buttons no longer than 0.5 seconds?
9.10.7 If a two-hand triggering facility has been installed, has the workplace been The monitoring system
designed as a one man workplace? may only exclude the
space actually occupied
by the operator's body.
Guards and safety devices
must be provided for all
other parts of the machine
(front, side and rear)!
Page: 8 of 11
10 Facilities that prevent parts falling Applies where there are protective
facilities / loads, which are raised by
means of electric / hydraulic /
pneumatic drives.
10.1 Have facilities been installed that prevent machine components falling or
dropping? Hydraulic / pneumatic check valves or mechanical fall arresters.
11 Hot and cold parts

Visual inspection
11.1 Have appropriate technical safety measures been taken to reliably prevent
personnel coming into contact with very hot or very cold parts?
11.2 Where this is not possible, is contact prevented by handling equipment or
personal protective equipment worn by the personnel?
11.3 Are the hot and cold surfaces marked accordingly?
12 Hazards caused by gas, vapor, mist, liquid and dust

Visual inspection, working zone analysis, test record
12.1 Have safeguards / extraction facilities been provided to restrain and/or to
discharge such emissions at source?
13 Hazards caused by breakage, bursting or shattering

Visual inspection, checking with reference to the operating manual
13.1 Have protective measures been implemented to protect personnel from hazards
caused by machine parts breaking, bursting and shattering?
13.2 Have all parts of the machine been fitted properly and securely and are all cables,
pipes, leads and hoses protected and secured? (e.g. by hydraulic, pneumatic and
thermal means)
Page: 9 of 11
14 Performing such production activities as setting, loading and

unloading
Visual inspection and function test, checking with reference to the operating
manual, the instructions for use and the work instructions
14.1 Do personnel have safe access to all of the areas required to perform the work?
14.2 Is it safe to remain in these areas while performing the work?
15 Maintenance, service, cleaning and debugging work Please use the LOCKOUT procedure
Checking with reference to the operating manual and the manufacturer's for this machine / equipment when
instructions. performing the safety check!
(FSS 1 requirements)
15.1 Do personnel have safe access to all of the areas required to perform the work?
15.2 Can maintenance, service, cleaning and debugging work be carried out without
removing the guards and safety devices?
15.3 Can all work associated with maintenance, service, cleaning and debugging be
performed with the machine at a complete standstill?
15.4 Are protective measures implemented when work has to be performed under
raised loads?
15.5 Are there any potential hazards associated with stored / residual energy?
(e.g. pressure vessels, hydraulic accumulators, electrical capacitors)
15.6 Are facilities provided that offer a means of releasing stored energy and de-
energizing the system, and are these facilities marked accordingly?
15.7 Are warning notices provided where it is not possible to release energy that is
stored in certain systems? (on the machine and in the operating manual)
15.8 Are the areas in which stored energy cannot be released completely marked in an
unambiguous manner?
15.9 Have checking cycles been defined for the guards and safety devices and are
these observed? (light barriers / emergency stop facilities)
15.10 Have work instructions been drawn up to stipulate the way in which the machine is
to be handed over for maintenance and repair purposes?
Page: 10 of 11
16 Protection against electric shock and indirect contact with electricity

Visual inspection
16.1 Do the machine and control facilities have protective equipment that prevents
electric shock? (e.g. proper safety class for enclosure, cable insulation, operator
control elements etc.)
16.2 Does the machinery / electrical system have protective equipment that prevents IEC 364-3
personnel coming into indirect contact with electric current in the event of an
insulation fault? (e.g. proper grounding, correctly dimensioned ground conductor,
grounding of the machine housing, insulation monitoring etc.)
17 Risk of personnel slipping, tripping or falling

(in connection with machines)
Visual inspection
17.1 Have measures been taken to ensure that personnel cannot slip, trip or fall?
17.2 Have suitable catwalks, platforms or intermediate platforms been installed to
ensure safe access to the equipment? For maintenance, cleaning, loading with
raw materials or removing the product at parts of the plant, which cannot be
reached from the floor, for example?
18 Ergonomics
18.1 Are the controller and operator control elements easily accessible?
18.2 Are the displays, indicators and measuring instruments required for operation
easy to read?
18.3 Are maintenance panels, manholes, inspection doors etc. accessible?
Page: 11 of 11

E FSS5 Attm1 General-Machine-Checklist Rev2 090330 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

E FSS5 Attm1 General-Machine-Checklist Rev2 090330 PDF

Uploaded by

Copyright:

Available Formats

FSS 5, Attachment 1:

General Machine Safety CHECKLIST

II. Details of the machine

Designation Type Serial No. Year of Manufacturer/ Location

III. Scope of the inspection:

IV. Results of the inspection

Person responsible for documentation,

VI. Inspection conducted by:

2 Intended purpose of machine and equipment

3 Lighting Safe conditions must be achieved in

4 Anchorage of the machine(s) / equipment and parts

5.2 If the operator is unable to see into the hazardous zone(s):

7 Control facilities (electrical, pneumatic and hydraulic)

8 Guards and safety devices Refer to EN 954 / ISO EN 13849 /

9 Risk of mechanical contact with moving plant components

9.8 Fixed guards and safety devices Refer to EN 953

9.9 Moving guards and safety devices Refer to EN 953

9.10 Other safeguarding methods Refer to EN 999.

11 Hot and cold parts

12 Hazards caused by gas, vapor, mist, liquid and dust

13 Hazards caused by breakage, bursting or shattering

14 Performing such production activities as setting, loading and

16 Protection against electric shock and indirect contact with electricity

17 Risk of personnel slipping, tripping or falling

You might also like