Use this checklist to identify common machine hazards during a machine safety assessment. (Check all that apply and note observations.)
Mechanical Hazards:
☐ Pinch Points (Nip Points) Areas where two objects move toward each other or one moves past another, creating a trapping point.
☐ Crush Points Locations where a body part can be caught between a moving object and a fixed surface.
☐ Shear Points Hazards created when two edges move across each other, or a moving edge passes a fixed edge.
☐ Cutting Hazards Exposure to sharp edges or tools capable of cutting or severing material or body parts.
☐ Entanglement Hazards Rotating components that can catch clothing, hair, or gloves.
☐ Drawing-In Hazards Points where a person or body part can be pulled into machinery through motion.
☐ Impact Hazards Moving machine parts that can strike a person.
☐ Stabbing / Puncture Hazards Pointed components capable of penetrating the body.
☐ Friction / Abrasion Hazards Surfaces that can cause burns or skin damage through contact or rubbing.
☐ Ejection (Thrown Parts / Material) Risk of parts, tooling, or debris being expelled from the machine.
Electrical Hazards:
☐ Electric Shock Exposure to energized electrical components.
☐ Arc Flash / Arc Blast High-energy electrical discharge that can cause burns or explosions.
☐ Static Electricity Discharge Build-up and sudden release of electrostatic energy.
Thermal Hazards:
☐ High Temperature (Burn Risk) Contact with hot surfaces, materials, or processes.
☐ Low Temperature (Cold Burn Risk) Exposure to extremely cold surfaces or substances.
☐ Fire Hazard Presence of ignition sources near flammable materials.
Chemical Hazards:
☐ Toxic Exposure Contact with or inhalation of harmful substances.
☐ Corrosive Materials Chemicals capable of damaging tissue or equipment.
☐ Combustible Dust Accumulation of fine particles that can ignite or explode.
Physical Environment Hazards:
☐ Noise Exposure Sound levels high enough to cause hearing damage.
☐ Vibration Exposure Prolonged exposure to vibration affecting health or performance.
☐ Radiation Exposure Presence of harmful energy sources (e.g., laser, UV).
Motion & Automation Hazards:
☐ Unexpected Startup Machine energizes without warning during maintenance or access.
☐ Loss of Control / Runaway Motion Failure of machine control leading to uncontrolled movement.
☐ Robot Interaction Hazard Human exposure to robotic movement or work envelope.
☐ Stored Energy Release Sudden release of pneumatic, hydraulic, or mechanical energy.
Ergonomic Hazards:
☐ Repetitive Motion Repeated movements that may lead to strain injuries.
☐ Awkward Postures Body positioning that increases physical stress or injury risk.
☐ Forceful Exertion Tasks requiring significant physical effort.
☐ Contact Stress Pressure applied to specific areas of the body over time.
Access & Egress Hazards:
☐ Slip, Trip, and Fall Risk Poor housekeeping, spills, or uneven surfaces.
☐ Restricted Access / Egress Limited ability to safely enter or exit machine areas.
☐ Working at Heights Exposure to elevated work areas without proper protection.
Control System & Functional Safety Hazards:
☐ Safety Circuit Failure Safety devices or systems not functioning as intended.
☐ Inadequate Safety Distance Insufficient spacing between hazard and safeguarding device.
☐ Bypass / Defeat of Safeguards Safety systems intentionally or unintentionally overridden.
☐ Lack of Control Reliability Single-point failure risk due to lack of redundancy.
Process & Operational Hazards:
☐ Human Error / Misuse Incorrect operation leading to hazard exposure.
☐ Poor Maintenance Practices Inadequate upkeep increasing likelihood of failure.
☐ Inadequate Training Personnel not properly trained on machine hazards or operation.
