Risk analysis of machines: cartoner and packaging machine

Machine risk control is crucial for safety and production efficiency. This applies in particular to intensively used devices. These include cartoning and packaging machines. The CMMS system provides a lot of support here – although it is not directly used for risk assessment, its functionality can be very helpful in this context. How does CMMS help reduce risk and increase production reliability?

Risk analysis for cartoners and packers

What is the purpose of risk analysis? There are three main purposes. These are the identification of hazards, the estimation of the probability of failure together with the consequences, and the preparation of the basis for the implementation of control measures. In the context of cartoning machines, which perform precise operations of folding and gluing boxes, and packaging machines – responsible for the final protection of products – risk analysis allows:

• ensure operator protection by minimising the risk of crushing, cutting or injury caused by moving parts;
• increase production continuity by reducing the number of failures;
• comply with regulations (health and safety standards, quality standards, industry requirements);
• improve maintenance processes by planning preventive work according to analysis results.

All this means that risk analysis can be considered the foundation of production safety. Its results should be closely integrated with the UR management system. This role is usually played by CMMS, which at the same time provides significant support for risk analysis.

Threat identification methods

The process of identifying threats consists of several stages. They can be carried out in various forms. Companies use workshops with the participation of operators and servicemen, as well as documentary techniques.

The first step is to review the technical documentation. Analysis of the operating instructions, machine diagrams and manufacturer data allows you to identify potentially dangerous points – such as clamping zones or areas with high air pressure. Then it is worth taking care to collect information from employees. What are the benefits? UR operators and technicians have daily contact with the machine, so they can provide practical information about the most common problems and irregularities.

It is also important to observe the processes and operation of the machine live. Direct visualization of the device’s operation is especially conducive to recognizing so-called dynamic threats. These include fast-moving elements, exposed gears or access points to dangerous zones. It is worth supplementing the whole thing with an analysis of the history of failures and accidents for this machine or similar devices.

Previously collected information can be collected in a document created according to a specific standard, e.g. HAZOP (Hazard and Operability Study) method. Why is it worth it? This structured approach allows for a transparent and understandable risk assessment. Based on these techniques, a full list of threats can be created, which are then assessed according to specific criteria.

Risk assessment for cartoner

A cartoning machine is one of the most popular devices on production lines. Its task is to fold and glue cardboard packages. What are the risk areas here? The most obvious are the clamping and cutting zones – gears, rollers or knives can lead to serious hand injuries. The analysis takes into account, for example, the probability of contact with a knife during an emergency insertion of a hand into the work zone.

If the cartoner uses a hot melt glue system, the risk of burns should also be verified. Another potential risk point is the automatic drive. What are the hazards? If there are no proper guards or the safety switch fails, rotating parts can catch clothing, creating a dangerous situation. If the cartoner uses a pneumatic supply, the high pressure can lead to the ejection of guards or loose parts.

During the risk assessment, each of the analyzed points is marked with an appropriate category – e.g. medium, low or high risk. When determining the category, both the probability of the event and its effects (material losses, injuries, downtime) should be taken into account. The results of this assessment are the basis for determining control actions. These in turn may include, for example, the installation of safety sensors, the implementation of mechanical guards or the implementation of power lockout procedures.

A packaging machine is a machine used to secure finished products, e.g. with heat shrink film or packaging tape. The key risks are somewhat similar to those of a cartoner. However, the challenges specific to this type of machine must be taken into account:

• Sealing zones – the heating elements of the packaging machine operate at temperatures reaching 200–300°C. Lack of appropriate shielding can result in operator burns. If there is contact with flammable materials, there is also a risk of fire.
• Moving film feeders – gears and rollers may cause loose parts of the operator’s clothing or body to be pulled in. This in turn generates a risk of mechanical damage and injuries among employees.
• Presence sensors – a typical element of a packaging machine is a product absence sensor. If it fails and the machine runs “dry”, it can overload the mechanical elements.
• Power supply and control – the main risk in this area is electric shock. This can occur as a result of improper electrical installation, worn wires or lack of overcurrent protection.

Again, each event should be described by the level of risk and the probability of its occurrence. This information is usually collected in a risk matrix. This is a simple way to visually compare the probability and consequences. This in turn is a significant aid in determining corrective and preventive actions.

The Role of CMMS in Risk Analysis

The CMMS system, although not directly acting as a risk assessment tool, significantly supports the entire process. Here are some features that provide assistance in this area:

1. Storing assessment results. After completing a safety audit or analysis, the results are transferred to the machine card in the CMMS. This allows each technician and operator to have access to a complete set of safety information.
2. Linked to machine history. Risk assessments are linked to data on inspections, repairs and failures. When the system generates a work order, it can immediately remind you to take into account the safeguards resulting from the risk analysis.
3. Preventive maintenance planning. CMMS can automatically suggest inspection or replacement of items based on risk level. The higher the risk, the more frequent the inspection reminders.
4. Alerts and notifications. If a failure related to a given threat occurs between inspections, the system can immediately notify the safety and maintenance departments. This allows for quick verification that the recommended controls are still in place.

This makes the CMMS a central knowledge point about risk for individual machines. Additionally, the system can be used to enforce continuous adherence to approved safety procedures. The result? Greater certainty, reduced risk, and improved transparency for the maintenance department.

Planning preventive actions according to risk analysis

Hazard identification is not the end. It is also crucial to supplement the analysis with the implementation of appropriate control measures. Here, we can distinguish technical, organizational and procedural measures. Technical measures include, in particular, the installation of additional safety elements – light barriers, switches, shields or monitoring systems. Organizational measures include work instructions, training or maintenance procedures. When it comes to procedural measures, we are talking about, for example, the introduction of checklists and schedules.

CMMS supports each of these stages. The system allows you to define preventive tasks for each identified risk and assign appropriate resources along with task completion dates. In addition, operators or technicians can easily confirm completed tasks and checks. Another advantage is monitoring effectiveness – especially in the case of recurring events from the same risk category. Thanks to this, risk analysis and planning of preventive services becomes a continuous, effective process based on objective and reliable data.

Risk analysis for cartoners and packers is a complex process that involves identifying hazards, assessing probability, and defining preventive measures. It is similar for other machines. CMMS does not replace risk assessment itself, but rather provides key support through its functionality. By implementing a comprehensive approach to risk analysis and a CMMS such as QRmaint, you can effectively manage hazards and ensure smooth, safe operation of your facility.