Risk assessment as the key to safety and innovation in mechanical engineering

NEERTEX – Your partner for tailor-made engineering solutions

From CAD design to special machine construction: Our claim

At NEERTEX, we combine years of expertise in mechanical engineering with state-of-the-art design and simulation methods. Our portfolio ranges from precise CAD design and sophisticated simulations to the entire special-purpose machine construction process and the necessary conformity assessment procedures. We place great emphasis on close collaboration with our customers – after all, every machine is unique and must be precisely tailored to your requirements. A systematic approach is particularly important in special-purpose machine construction. Risk assessment indispensable. Our engineers are not only technically competent, but also understand the importance of developing practical solutions. We always operate at the intersection of safety, cost-effectiveness, and innovation. Whether you're planning a highly complex production facility, developing a new packaging machine, or need custom solutions for particularly challenging processes – we're your reliable partner.

What exactly is a risk assessment?

The basics according to the Machinery Directive 2006/42/EC

The Risk assessment is loud Machinery Directive 2006/42/EC a legally prescribed process that every manufacturer—and in many cases also operators, importers, or general contractors—must complete. Annex I of this directive clearly states:

"The manufacturer of machinery or his authorized representative must ensure that a risk assessment is carried out to determine the safety and health requirements applicable to the machinery. The machinery must then be designed and constructed taking into account the results of the risk assessment."

This is by no means merely a formal requirement. Rather, risk assessment is the heart of machine safety: It uncovers sources of danger, assesses the extent of potential damage, and considers the probability of its occurrence. In other words: While hazards are strongly linked to scientific principles (e.g., mechanical forces, chemical reactions), Risk Analysis The focus is on the interaction between humans and machines. Only then does it become clear which measures are necessary to protect people, the environment, and operations.

Risk analysis vs. risk assessment – ​​what’s the difference?

In common parlance, risk analysis and risk assessment are often used synonymously. However, they are actually interrelated but distinct steps:

1. Risk Analysis:
   • Essentially, this is about investigating the hazards and their potential impacts.
   • The question is what could happen when a machine is in operation (or during assembly, maintenance, transport, etc.).
   • Scientific findings, empirical values ​​and industry-specific characteristics are incorporated here.
2. Risk assessment:
   • Based on the previous analysis, an assessment is made as to whether an identified risk is acceptable or not.
   • Limit values, legal requirements, corporate responsibility and human factors play a decisive role.
   • A central goal: to derive and implement appropriate protective measures until an acceptable residual risk remains.

  This is how a Risk Management-Cycle that ensures that the machine is checked from different perspectives by considering hazards, probabilities and serious consequences together.

Historical perspectives and economic significance

Risk as an opportunity – A look at the origin and change of the term

Interestingly, the term "risk" in German usually has a negative connotation, associated with danger or uncertainty. Originally, however, the word may derive from the Arabic "risq," which is thought to have meant a positive "gift" or "allotment of luck." Only over the centuries did the concept of risk develop into what we understand it to be today: a venture where adverse consequences may occur, but are not inevitable. However, this is particularly true in mechanical and plant engineering: Risk is the flip side of opportunity. Those who act without risk often forego technical innovations and thus competitive advantages. Risk assessment Therefore, it not only serves to protect employees and the environment, but also forms the basis for bold, safe, and well-thought-out innovations. At NEERTEX, we take precisely this connection into account: We identify hazards, assess potential damage, and systematically weigh opportunities and risks to offer you the greatest possible benefit.

Which standards and guidelines are relevant?

DIN EN ISO 12100 and DIN EN ISO 13849

The Machinery Directive is supported by numerous harmonized standards Of utmost importance is the standard DIN EN ISO 12100:2010 (Safety of machinery). She describes:

• General principles for Risk assessment and risk mitigation
• Uniform terms and definitions
• Systematic procedures, such as identifying and assessing hazards

  Equally important in the context of control technology is the DIN EN ISO 13849-1 and -2This involves a thorough evaluation of the reliability of functions such as emergency stops, safety doors, and light curtains. Only when it is ensured that these safety-relevant components are designed according to the required performance levels is the entire machine compliant. A real-world example: If you operate an assembly line with automated robots, you must ensure that all emergency stop circuits, limit switches, and monitoring functions meet the safety requirements. In the event of an unexpected standstill, the robot must remain within safe limits without endangering people or equipment.

The benefits of a professional risk assessment for companies

From legal certainty to added value

 

• Legal certainty A thorough risk assessment protects you from liability risks and ensures that your machines meet legal requirements. Should a legal dispute arise, comprehensive documentation is invaluable – after all, lawyers are retrospective and detail-oriented. This is precisely where we at NEERTEX come in: Our documentation is clearly structured and follows established standards, so you're well prepared in case of doubt.

   

• Optimized processes and reduced downtime By uncovering hidden vulnerabilities in the early design phases, you can minimize later production downtime. Recognizing potential hazards and implementing appropriate countermeasures creates more stable processes in the long term. Our team focuses not only on technical safety but also on operational suitability—we think in terms of holistic solutions.

   

• Economic efficiency and innovation Innovative machines and systems often offer a clear competitive advantage. But without a sound Risk Analysis Exciting ideas are quickly discarded or run the risk of being too risky. A professional risk assessment, on the other hand, gives you the foundation to take calculated risks that pay off. We support you in optimizing the risk-benefit ratio.

   

• Improved team dynamics A conscious approach to risks promotes communication between designers, operators, and safety officers. A transparent approach to hazard sources facilitates knowledge transfer and motivates all involved to actively contribute to safe solutions.

 

How NEERTEX conducts a risk assessment

Step-by-step to a safe machine

1. 1. Analysis of the initial situation We work with you to define the requirements for your special machine. Whether it's a complex assembly machine or a robot-assisted palletizing system, we take the time to understand your processes and goals in detail. At the same time, we review the relevant standards and guidelines.

 

• Identification of hazards Our experienced engineers identify all sources of hazards, from mechanical movements and physical influences (e.g., noise, vibrations) to chemical or thermal risks. We work closely with the client to ensure no details are overlooked.

   

• Risk assessment In this step, the probability of a hazardous event occurring is compared to the potential extent of damage. This makes it clear which risks are intolerable and how high they should be prioritized. We often rely on proven methods for this, such as the simple yet effective risk matrix process.

   

• Determination of protective measures To reduce risks, we propose targeted technical, organizational, or personal protective measures. In doing so, we are guided by the 3-step method the risk assessment:

 

• Design measures (e.g. covers, safe distances)
• Additional protective devices (e.g. light curtains, emergency stop devices)
• User information and warnings (e.g. labels, operating instructions)

 

• Documentation All identified hazards, risk assessments, and measures are systematically recorded. This is not only a legal requirement but also an essential part of your technical documentation. It also serves as the basis for regular reviews and updates should the machine be modified or expanded.

 

A practical example from special machine construction

Imagine you want to develop a new special-purpose machine for automated PCB assembly. The system is designed to precisely pick up small electronic components and place them on a conveyor belt. Our team at NEERTEX proceeds as follows:  

• Hazard: Moving parts Due to the rapid and repetitive movements of the gripper arm, there is a risk that people could be caught. Our Risk Analysis shows that even minor collisions can cause serious injuries. Components could also be damaged by vibrations or incorrect motion profiles.

   

• Measure: Protective enclosure and collaborative robots We opted for a transparent protective enclosure that prevents operators from accidentally entering the gripper arm's working area. Alternatively, a collaborative robot could be used that automatically slows down or stops when a person approaches too closely.

   

• Result: High process reliability Through these measures, we reduce the risk of personal injury to an acceptable level while creating a highly automated, reliable production environment. The machine is safe, efficient, and meets all quality and performance requirements.

 

Counterarguments and Limitations – Why Some Companies Hesitate

Time and cost expenditure versus long-term benefits

A common counterargument is: “The Risk assessment "It's time-consuming and expensive." Indeed, a thorough analysis requires resources and expertise. Companies that think in the short term sometimes shy away from the investment. But those who inadequately assess machinery and potentially implement non-compliant solutions can later face high follow-up costs – from liability issues to production downtime. Furthermore, the necessary expertise in risk assessment and Risk Analysis Not available in every company. This is where NEERTEX comes in: As a specialized engineering firm, we provide you with professional support and relieve your team of time-consuming analysis steps. This way, together we turn your ideas into reality without you having to compromise on safety and quality.

Future outlook – How risk assessment will evolve

The increasing digitalization and automation constantly bring with them new risks. Topics such as Artificial Intelligence or machine learning They are playing an increasingly important role in process optimization and presenting designers with new challenges. This is no longer just about mechanical hazards, but also about data integrity or cyberattacks that could manipulate machines. In the future, the Risk assessment even more closely with holistic Risk Management-approaches. This means that, in addition to traditional physical threats, aspects such as data and information security, network stability, and energy efficiency are also becoming more important. NEERTEX already relies on interdisciplinary methods to offer our customers solutions that will remain sustainable for years to come.

Why NEERTEX? – Your trusted partner for safety and efficiency

Our promise to you

 

• Cross-industry expertise Whether packaging technology, automotive, food industry or medical technology: We have experience in a wide range of industries and can transfer best practices.

   

• Practical solutions Through our many years of project experience, we know that technical perfection and economic rationality must go hand in hand. Our risk assessments are actionable and take your individual cost-benefit framework into account.

   

• Close cooperation and personal support We maintain open communication, involve your teams early on in the development process, and remain your contact for questions and optimizations even after a project has been completed.

   

• Clear documentation From the initial brainstorming session to the final machine acceptance, we provide clear and comprehensible documentation. This ensures that you can provide information about your machine and its residual risks at any time.

 

Conclusion – Shaping the future safely with NEERTEX

The Risk assessment is a central element in modern mechanical engineering. It enables early detection of hazards and the implementation of appropriate countermeasures, thus not only increasing safety but also unlocking efficiency and innovation potential. Particularly in special-purpose machinery, where individual solutions are essential, a well-thought-out Risk Analysis Indispensable. At NEERTEX, we place the utmost importance on providing our customers with professional support throughout this process – from the initial concept and design to legally compliant documentation. We are familiar with legal requirements and relevant standards, possess extensive experience across diverse industries, and develop customized concepts that are both technically sound and economically viable. Our outlook for the future of mechanical engineering is optimistic: technologies are becoming smarter, processes more efficient, and globalization is offering new business opportunities. To capitalize on these opportunities, safety must be understood as an integral and indispensable component of every machine concept. Risk assessment and Risk Analysis are not burdensome duties, but rather a key that unlocks efficiency, innovation and trust in equal measure.

Contact us now – Seize opportunities and manage risks together

Are you ready to realize your next special machine project safely and successfully? Would you like to benefit from our expertise in Risk assessment and Risk Analysis Would you like to benefit from this? Then contact us at NEERTEX today. Together, we'll find the optimal balance between technical innovation, economic profitability, and maximum safety – so that your special machines can remain successful and legally compliant on the market for the long term. Rely on NEERTEXto meet the challenges of the future. We look forward to supporting you with our expertise and passion for mechanical engineering and providing you with a solution that precisely meets your requirements.