Reducing risk on machinery: a field evaluation pilot study of risk assessment

A pilot evaluation of the ANSI B11-TR3 Machinery Risk Assessment/Risk Reduction (RA/RR) Guideline was conducted. The TR3 guideline was introduced into five companies on one machinery system in each company with a second machine system serving as a control. A pre-post investigation was performed with safety conditions measured pre and post in both treatment and control and with risk reduction score measured only in the treatment machine system. NIOSH provided a commercially available risk assessment software to facilitate the process. Evaluation measures included avoided injuries, reduced exposure to machinery hazards, pretest and posttest knowledge demonstration, assessment of group processes following training, correct implementation of the guidelines, and degree to which risk reduction recommendations were implemented. The qualitative results of this pilot effort appear to be the best indicators for the way ahead in industrial machine risk assessment. All companies indicated that they derived value in participating in this study and in conducting risk assessments. Quantitative study results suggest that: (1) as measured by the knowledge of the participants before and after the TR3 training, the guidelines can be effective at enhancing employee knowledge of safe machine operations and (2) although the injury reduction trends appear successful, the small sample size in the study size should be considered in interpreting these early results.