Automation Risk Assessment — Conveyors & Robotic Cells

Who it’s for

• Facilities with conveyors, robotic cells, automated storage, sorters, or custom machinery

• New installs, modifications, near‑misses/incidents, or insurer/customer mandates

What’s included

• System walkdown: hazards, safeguarding, emergency stops, access points

• Guarding/interlock verification (mechanical/electrical), safe distances, reach

• Task‑based risk assessment (severity/probability/exposure)

• LOTO points identification and isolation verification

• Operating modes (auto/manual/maintenance) and safe speed checks (where feasible)

• Signage/labels, procedures, training needs

• Photos, risk ratings, and standards references

Deliverables

• Risk register with ratings and rationale

• Guarding/interlock gap list with practical remedies

• Marked layouts identifying LOTO points and access controls

• Draft SOPs and LOTO procedures (scope‑dependent)

• Corrective Action Plan with owners and due dates

• Review call and final report (PDF)

Process

1. Scope call (systems, OEMs, line drawings, goals)

2. Document review (P&IDs/layouts, OEM manuals, controls narratives)

3. Onsite assessment and interviews (ops/maintenance/engineering)

4. Draft report and CAP

5. Review, finalize, and schedule follow‑up

Pricing

• From $9,500 (typical single cell); multi‑line projects & full systems quoted

• Timeline: 2–4 weeks depending on scope and access

• Add‑ons: Controls partner for validation, engineering for racking/structures, training bundle

Service area

• Chicago & West Chicagoland; travel T&M outside local area

Standards referenced

• OSHA 1910 (Subparts O/S), ANSI B11 series, ANSI/RIA/ISO 10218, ISO 12100, ISO 13849, IEC 62061, ANSI Z244.1 (LOTO), applicable IBC/IFC

Client preparation

• Provide layouts, P&IDs or line drawings, OEM manuals, controls descriptions

• List of operating modes, maintenance tasks, and access procedures

• Identify known issues, recent incidents/near‑misses

FAQs

• Do you test safety circuits? We verify function and documentation; full validation can be coordinated with a controls partner.

• Can you provide SOPs and LOTO? Yes—drafts included when in scope; full program builds available.

• Will this require downtime? Limited; brief stops may be needed to verify guards/interlocks and LOTO points.

• Can you support new installations? Yes—pre‑start reviews and post‑commissioning assessments.