ISO 12100:2010 – Safety of Machinery – General Principles for Design – Risk Assessment and Risk Reduction

1. Machinery Safety Principles and ISO 12100 Requirements :

Introduces machinery safety terminology, ISO 12100 principles, legal responsibilities, machinery lifecycle considerations and the importance of systematic risk assessment.

2. Machinery Limits and Hazard Identification :

Develops knowledge of machinery limits, intended use, reasonably foreseeable misuse, mechanical hazards, electrical hazards, thermal hazards, noise, vibration and ergonomic risks.

3. Machinery Risk Assessment and Evaluation :

Covers hazard identification, risk estimation, severity of harm, probability of occurrence, exposure, possibility of avoidance and systematic risk evaluation.

4. Risk Reduction and Protective Measures :

Examines inherently safe design, engineering controls, machine guarding, protective devices, interlocking systems, emergency stopping and complementary protective measures.

5. Machinery Safety Verification and Documentation :

Develops knowledge of risk-assessment records, safety validation, inspection documentation, technical files, safety instructions, warning systems and verification of risk-reduction measures.

6. Practical Machinery Risk Assessment and Integrated Project :

Integrates learning through machinery case studies, hazard registers, risk evaluation, selection of protective measures, residual-risk assessment and preparation of a complete machinery safety report.

• Develops knowledge of ISO 12100 machinery safety principles.

• Builds practical machinery hazard identification skills.

• Strengthens machinery risk assessment and evaluation capabilities.

• Develops understanding of the three-step risk-reduction methodology.

• Improves knowledge of machine guarding and protective devices.

• Introduces safety-related control system requirements.

• Strengthens understanding of machinery lifecycle safety.

• Develops skills in machinery safety documentation and reporting.

• Improves understanding of foreseeable misuse and residual risks.

• Supports machinery safety compliance and engineering risk management.

• Provides a foundation for further study in functional safety and machinery engineering.

This programme is suitable for:

• Machinery safety professionals.

• Mechanical and industrial engineers.

• Machinery designers and design engineers.

• Manufacturing and production supervisors.

• Plant and equipment managers.

• Maintenance engineers and technicians.

• Occupational health and safety professionals.

• Machinery risk assessors.

• Engineering consultants.

• Machine manufacturers and equipment suppliers.

• Safety officers responsible for machinery-related hazards.

• Quality assurance and engineering compliance personnel.

Assessment Format: Written knowledge examination, multiple-choice questions, machinery safety case studies, hazard identification exercises, risk assessment assignments and a practical machinery safety project.

Total Questions: 50 written questions across the knowledge assessment components, supplemented by practical assessments and an integrated machinery risk assessment project.

Passing Score: 60% in the written examination, together with satisfactory completion of all mandatory practical assignments and project requirements.

Duration: 90 minutes for the written examination, with separately scheduled time for machinery assessment exercises and project submission.

Certification: Successful learners may receive the HiQual UK Certificate in Safety of Machinery – Risk Assessment and Risk Reduction, subject to programme approval and applicable assessment requirements.

To deliver this Qualification, HiQual UK Approved ATPs must demonstrate the capability to deliver, assess, and internally quality assure qualifications in line with recognised regulatory principles and the expectations of the Regulated Qualifications Framework (RQF).

Approved centres must operate effective systems to ensure the validity, reliability, fairness, consistency, and security of assessment.

1. Centre Recognition and Legal Compliance

Centres must be formally recognised by HiQual UK prior to the delivery or assessment of any qualification. To maintain recognition, centres must: Be a legally constituted organisation operating in compliance with applicable legislation and regulatory requirements. Demonstrate effective governance, management oversight, and clear lines of accountability. Comply with all HiQual UK policies, procedures, and conditions of centre recognition. Notify HiQual UK promptly of any material changes that may affect delivery, assessment, or internal quality assurance arrangements.

2. Resources, Facilities, and Learning Environment

Centres must ensure that sufficient and appropriate resources are in place to support learning and assessment. This includes: Learning environments appropriate to the mode of delivery, including classrooms and, where applicable, specialist or practical facilities. Access to learning and assessment resources that enable learners to meet qualification outcomes. Secure systems for managing learner data, assessment records, and certification claims. Arrangements that support equality of access and reasonable adjustments for learners where required.

3. Staff Competence and Occupational Expertise

Centres must ensure that all staff involved in delivery, assessment, and internal quality assurance are competent and suitably qualified. Centres must: Appoint tutors with appropriate subject knowledge, teaching competence, and relevant occupational or professional experience. Ensure assessors are trained and competent in applying HiQual UK assessment requirements and standards. Appoint a qualified Internal Quality Assurer (IQA) responsible for monitoring assessment practice and decisions. Maintain records of staff qualifications, experience, training, and continuing professional development (CPD).

4. Assessment Practice and Internal Quality Assurance (IQA)

Centres must operate robust internal quality assurance systems to ensure assessment integrity. Centres must: Ensure assessment is valid, fit for purpose, and conducted in line with HiQual UK requirements. Implement effective IQA procedures to monitor assessor performance and confirm the consistency of assessment decisions. Maintain accurate, complete, and auditable records of learner registration, assessment evidence, and outcomes. Carry out regular internal reviews and standardisation activities to support continuous improvement.

5. Integrity, Risk Management, and Malpractice

Centres must take appropriate measures to protect the integrity of assessment. Centres must: Maintain policies and procedures for the prevention, identification, and management of malpractice and maladministration. Ensure secure handling, storage, and retention of assessment materials and learner evidence. Report any suspected or confirmed malpractice to HiQual UK in accordance with published procedures.

6. Health, Safety, Safeguarding, and Learner Protection

Centres must provide a safe, inclusive, and supportive learning environment. Centres must: Comply with applicable health and safety and safeguarding legislation. Conduct risk assessments for learning activities, particularly where practical or technical work is involved. Maintain procedures to safeguard learner welfare and wellbeing.

7. Learner Information, Support, and Fair Treatment

Centres must ensure learners are informed, supported, and treated fairly. Centres must: Provide clear and accurate information on programme requirements, assessment methods, and certification. Ensure learners receive timely and constructive feedback on assessment outcomes. Operate transparent complaints and appeals procedures aligned with HiQual UK requirements. Manage learner information securely in compliance with data protection legislation.

Successful learners may progress to:

• Further study in machinery safety, mechanical engineering and industrial risk management.

• Advanced training in machinery risk assessment and risk-reduction engineering.

• Specialist training in functional safety and safety-related control systems.

• Professional development in machine guarding, protective devices and interlocking systems.

• Further qualifications in occupational health and safety, engineering management and industrial safety.

• Specialist training in machinery conformity assessment and product safety.

• Career development toward Machinery Safety Officer, Machinery Risk Assessor, Engineering Safety Coordinator or Manufacturing Safety Specialist roles, subject to relevant experience and employer requirements.