Discovery tool

Machine Guarding Risk Scorecard

Most plants don't have a guarding problem they can name — they have eleven of them, unranked, and no way to argue which one to fix first. Add a machine, answer nine questions, repeat as you walk. You'll get a scored and ranked register showing where the exposure actually is, what's driving each score, and what to do next.

Faztek Industrial Solutions
Machine Guarding Risk Register

Your machines

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How the score works

Each machine is scored 0–100 across six weighted factors. The score is a prioritisation aid — it tells you which machine to look at first, not what the required safety performance level is. That determination comes from a risk assessment by a competent person.

FactorMaxWhy it's weighted that way
Hazard severity22What the machine can actually do to someone. Ejection, crush and shear score highest.
Guard condition24No guard and a defeated guard score close together, because both leave the hazard reachable.
Interlock status20A defeated interlock scores higher than a missing one — it means someone made a deliberate decision to work around it.
Bypass evidence18Observed workarounds are the strongest predictor of an incident, because they show the guard is losing an argument with production.
Exposure10How many people, how often they're inside, and whether the machine can run while they are.
Audit & incident history6Open findings and near misses raise urgency without inflating the underlying physical risk.

Important limits

  • This is not a risk assessment. It does not determine required performance level, safety category, safe distances or guard height, and it is not a substitute for ISO 12100 / ANSI B11.0 methodology or your own EHS process.
  • It reflects what you observed on a walk. A machine can score Low here and still have a serious hazard that isn't visible from outside the guard.
  • Scores are relative, not absolute. They rank machines against each other in your plant. A score of 40 is not "acceptable" — it's "less urgent than the 70."
  • A defeated interlock is an immediate issue regardless of what this tool says. It should be escalated the day it's found, not scheduled.

This scorecard produces a prioritisation aid from the observations you enter. It is not a safety approval, a compliance determination, or a quotation. Have findings reviewed by a competent person under the standards applicable to your facility.

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Risk distribution

Your register is saved in this browser only — nothing is sent anywhere unless you choose to send it.