Risk Assessment Discussion

Within every new project, there are various elements of risk

which must be considered and managed.
For our project, the risk assessment has been split into two
areas, one which considers all of the health and safety aspects
and one which considers risk involved with project, technical
and commercial issues.
The health and safety area of the risk assessment looks at
potential risk surrounding both foreseeable use and foreseeable
misuse. Using the scale from 1 to 5 for the severity of the
consequence of each described risk, and a scale of Low,
Medium and High for the likelihood, it is possible to rank the
risks to produce a Prioritised Risk Assessment. Once this has
been produced, mitigations for each of the risks can be
introduced.
We will now look at each risk described in more detail and
explain more comprehensively what is meant by each risk and
its mitigation.
Deliberate breaking of maximum boundaries and limits, deals
with the possibility of the user trying to exceed the capabilities
of the machine. Attempting anything which will compromise the
performance of the machine could result in machine failure and
subsequently injury. The likelihood of such events occurring has
been stated as medium and the consequence involving
Moderate Injury. The mitigation as described for this risk is to
display a comprehensive list of what not to do whilst using the
machine and for this particular risk state that the machine
should only be used within the stated boundaries.
Incorrect use of the pull down bar is a risk associated with
both accidental and deliberate misuse of the pull down bar.
Using the pull down bar for any exercise other than those
shown on instructional diagrams on the machine can lead to
damage to the machine and also injury to the user. The
likelihood of this risk occurring can be classed as medium and
the consequence Minor Injury. This risk can be mitigated by
displaying easy to understand instructional diagrams on the
machine from which the user can determine the correct way to
handle the pull down bar.
Applying too much weight will result in injury is directly
associated with deliberate misuse of the system by the user. If
the user instructs the machine to deliver more weight than
he/she is comfortable with then the result for the user will be
injury. It is much more advisable for the user to begin their
workout on a lower weight and then build the weight up in
accordance with what they are capable of and feel comfortable
with. The level of likelihood applied to this risk is medium and it
falls into the Minor Injury category of the consequence scale.
The mitigation suitable for this risk is within a comprehensive
list of what to do displayed on the machine and should state
that the user should not try to apply weight which exceeds
what is suitable for them.
Body parts coming into contact with moving parts is
associated with the users deliberate misuse of the machine.
The large moving parts are generally the pulleys connecting the
pull down bar to the rest of the application system. Fingers or
hands coming into contact with such moving parts can result in
friction burns and other minor injuries. The likelihood of this risk
occurring is medium and as stated, the consequence of it
happening would result in Minor Injury. A list of what not to do
when using the machine, which is visible to the user, would be
an appropriate mitigation for this risk, and would state that all
body parts should be kept away from exposed moving parts.
Use of inappropriate exercises is a necessary risk to include in
the health and safety risk assessment to cover foreseeable
misuse of the system by the user. The machine has been
designed to perform specific exercises and these will be
demonstrated by instructional diagrams on the machine.
Attempting to perform other exercises with the machine may
result in damage to the machine itself and injury to the user.
The likelihood of this risk is medium and the level of
consequence which will result would be Minor Injury. The
method of risk mitigation which can be applied for this risk
involves instructional diagrams in place on the machine which
will inform the user of which exercises are appropriate and how
to perform them correctly.
Incorrect exercise technique will result in injury is a risk
included within the risk assessment as it is very common for
users of weight training machines to employ bad technique.
Often, poor technique which is repeated over a period of time
can result in injury to the user. Of medium likelihood, the
consequence of this risk falls into the category associated with
Minor Injury. Instructional diagrams presented on the machine
will enable users to be constantly reminded of what is the
correct technique.
Incorrect positioning of the seat is a risk which can be avoided
by diagrams clearly displayed on the machine of how to
correctly position the seat. In order to correctly perform the
desired exercises the seat must be positioned correctly and
therefore if it is not the user will perform substandard exercises
and most likely experience some unnecessary discomfort too.
The likelihood associated with this risk is medium and as
explained the level of consequence resulting from this risk is
Discomfort. Providing diagrams for the user to follow is a
suitable mitigation for this risk, showing how to properly adjust
and position the seat.
Opening up/disassembly of the motor box is a risk of low
likelihood but one which results in severe consequences. Within
the core box is contained the motor and the brake, both of
which are potential sources of electrical hazards if disturbed. As
the core box is also connected to the mains this also presents
dangers of electric shock if interfered with. The consequences
of opening up/disassembly of the motor box could result in
Severe Injury to the user. The mitigation to be applied to this
risk involves displaying clear warning and hazards sign on the
outside of the motor box visible to the user and instructions not
to disassemble.
Interference with the cable and pulley set up is a risk which
will have severe consequences. The cable and pulley
arrangement has been designed so that it works in perfect
conjunction with the rest of the system and therefore should
not be altered. The likelihood of interference is low. However, if
it was to be interfered with, Severe Injury could result. The
cable could become loose or detached which would have
obvious disastrous repercussions for the user. Therefore, the
user must be informed of the severity of such actions and it
must be included in a list of what not to do which should be
clearly displayed on the machine.
Making unauthorised adjustments will have obvious effects on
the performance and safety of the machine. Unauthorised
adjustments could compromise the safety of the machine in
many ways and to varying levels of severity. The maintenance
of the machine is not the responsibility of the user but the
manufacturers and therefore under no circumstances should
the user tamper with the workings of the system. Although a
low likelihood, the consequence of this risk could result in
Severe Injury for the user. It will be made clear to the user
that they should make no adjustments to the machine. This will
also be clearly displayed on the machine itself.
Deliberate destruction is a risk which must be considered but
one which is of low likelihood. Deliberate destruction is an
example of foreseeable misuse of the machine by the user and
therefore must be accounted for. Deliberate destruction can
involve anything from direct abuse of the machine itself to. The
consequences of such actions can result in Severe Injury to
the user if the machine is then used. It must be made clear to
the user than any form of deliberate destruction of the machine
will compromise the safety of the machine and subsequently
result in injury.
Use of the equipment out doors is a risk which covers the
machine being moved and used outdoors. The machine is not
designed to be waterproof or in fact windproof and therefore
will not perform effectively if used in such conditions. Although
the likelihood of these situations occurring is low, due to the
consequence can result in Moderate Injury. The machine will
not perform predictably in exposed conditions and therefore is
a substantial risk. All users should be instructed that the
machine should not be used outdoors.
Inserting body parts into moving parts is a risk which is
considered to be of low likelihood yet can result in Moderate
Injury if the risk occurs. There are several moving parts within
the machine all of which should be avoided when the machine
is in use and under no circumstances should body parts,
particular fingers, be deliberately inserted. It should be made
very clear to the user that this is the case and that there is a
high risk of injury if done so.
Use of the equipment when suffering from injury is a risk
which must be considered for all forms of exercise equipment. If
somebody were to use the equipment when they had an
existing injury, continuing to exercise could make the injury
worse. The likelihood of this risk is low yet Moderate Injury can
result. Risk mitigation involves instructing all users that they
should consult their doctor before embarking upon any exercise
regime, especially if already suffering from an existing injury.
Body parts becoming caught in moving cable is a risk of low
likelihood yet of fairly substantial consequence. This risk is
largely associated with hands and fingers become tangled in
the moving cable aspect of the system. It is evident that if this
were to happen then injury would result and hence the injury
associated with this risk is Moderate Injury. Risk mitigation
involves stating on the machine what not to do list that all body
parts should be kept well clear of all moving parts during
operation.
Liquids will cause damage if they come into contact with the
system refers largely to the risk that is presented if liquids
come into contact with the core box containing the motor which
is connected to mains power supply. The likelihood of this risk
occurring is low but the consequence is somewhat higher
resulting in Moderate Injury. Within a comprehensive list of
what not to whilst using the machine it will be included that no
liquids should come into contact with any of the working parts
of the machine.
Use by those above or below the maximum and minimum
percentiles is a risk associated with users who fall either above
or below the height and weight maximum and minimum
percentiles. The maximum and minimum figures will be
displayed and anybody who uses the machine outside of these
boundaries will be at risk of injury and potentially at risk of
causing damage to the machine. The risk likelihood is low as
there are only a ten percent of people who are not suitable to
use the machine, yet the consequence can result in Moderate
Injury. Risk mitigation involves using a not to do list which will
be displayed on the machine as a method of
reminding/informing users if they should not be using the
machine.
Body parts caught in the seat adjustor pin is largely concerned
with fingers becoming trapped when using the seat adjustor pin
to adjust the height of the seat. The design of the seat and the
pin mean that the likelihood of body parts becoming trapped is
low yet there is a consequence of Minor Injury if this does
happen. Outlining and emphasising that extreme care should
be taken when adjusting the seat height using the seat adjustor
pin in the list of what not to do when using the machine will be
the mitigation for this risk.
Incorrect use of the seat is a risk of both low likelihood and low
consequence. This risk involves the seat being used for
purposes other than its primary function or in the way in which
it was intended to be used for the purpose of the exercises to
be performed. The consequence category that this falls into is
Discomfort as no significant level of injury would result from
incorrect use of the seat. The risk, however, can still be
mitigated. Mitigation of the risk can be achieved by including
instructional diagrams on the machine to allow the user to see
the appropriate and correct way of using the seat.
Clothing becoming caught/trapped in moving parts is a risk
which would involve the users clothing coming into contact
with, and then subsequently becoming trapped, in the moving
parts of the machine. The chances of this happening are fairly
low and the risk is therefore represented by a low likelihood.
The consequence associated with the risk is one causing
Discomfort as the effects of clothing becoming caught would
be minimal. In order to mitigate this risk it should be outlined
that clothing should be kept clear of all moving parts and more
specifically that excessively loose clothing should not be worn
when using the machine.
Body parts inserted into core box fans is a risk considered to
be of low likelihood. There are two cooling fans on either side of
the core system box and if body parts, such as fingers, were
inserted into these when they are stationary they could become
stuck, and if they came into contact when the fan was moving
then there is risk of slight injury. The consequence category
which this risk falls into is that which covers Discomfort. In
order to mitigate this risk it should be stated in the list of what
not to do that body parts should be kept away from the fans.
Prolonged pull down position could burn out motor is a risk
which could occur as a direct result of user misuse. If the pull
down bar is held in the down position for a prolonged period of
time if will require a lot of output from the motor and therefore
could result in the motor eventually burning out. The likelihood
of this risk is low as it would have to be a fairly substantial
amount of time for the motor to burn out, and the consequence
is also classed as low falling into the category which would
cause Discomfort. In order to mitigate this risk it could be
included into the what not to do list that the user must not
maintain the pull down position for any length of time and
should instead return the bar to its original resting position
immediately when the exercise is complete.

The area of risk concerned with project, technical and

commercial issues is an extremely important one and one
within which there could be the most project threatening risks.
The purpose of the three different categories within the overall
Design and Commercial section of the risk assessment is so
that each risk can be dealt with more easily and specifically.
The risks are initially assessed by their likelihood and
consequence using a scale of low, medium and high. Those
with a combined result of high-high represent those risks most
fatal for the project and ones which must be most urgently
considered before proceeding. In contrast, those with a low-low
outcome are the risks considered to be least significant and are
not as highly regarded.
Outside the scope of existing expertise is a risk of high
importance due to the severe consequences which would result
from it. This risk involves discovering areas of the project which
require understanding and knowledge which is beyond that of
the project members. This could be largely associated with the
control aspect which involves a substantial amount of highly
specific and precise knowledge. Due to the slightly unknown
nature of this control element, the likelihood of such a risk
occurring is medium and the consequence is high. Discovering
such gaps in our knowledge would halt our progress and as
such present severe repercussions in terms of time and budget
constraints. In order to solve such a situation the area of the
project in question could be either subcontracted to specialists
or specialists could be employed into the project to assist.
Core system unable to match conventional weight system
performance is a factor of this system which has been thought
about in detail from the start. The idea of this new modular
system is to replace the need for block weight and provide an
alternative and superior resistance method. If this however
does not truly simulate the original experience then the system
is flawed. The likelihood of this risk is medium and the
consequence high. If the performance of the system fails to
imitate the experience created by block weights then the
resistance method would need to be reassessed and
redesigned.
Control system cannot accurately distinguish when to swap
between brake and motor mode is a risk associated with the
changeover between when the control system is actively
engaging with the brake and the motor. The downward pull of
the pull down bar is resisted by the motor and on the upward
movement the resistance is provided by the brake. If the
control system does not swap between these two efficiently
then the motion will not be fluid and will be awkward for the
user to deal with. The likelihood of this risk occurring is medium
and the level of consequence which it will result in is high. The
simplest mitigation for this risk would be to remove the brake
system and redesign the control system to run both the upward
and downward motions of the motor.
Motor does not provide required power is associated with the
risk involved if the motor we have chosen for our system fails
to provide enough power to support the resistance method. Our
calculations have led us to choose a 24V motor but if our
calculations prove inaccurate and this voltage is insufficient
then the system will fail. The likelihood of this happening is low,
we trust all our calculations to be correct and therefore there is
no foreseeable reason that the motor will not provide sufficient
power. However, the consequence which would result if this risk
were to materialise would be high. The mitigation for this risk
would simply be that a larger motor would have to be sourced.
Completed application system does not meet strength
requirements is a risk which may also be considered as a
safety hazard. If the completed system is in fact not strong
enough to support its own weight and that of the users then
there are large risks involved. Although the likelihood of the
system doing anything other than excelling the strength
requirements if low, the consequences if it does not are high.
Reinforcements would be required in order to ensure that the
strength of the machine is sufficient.
Application system design unstable is a risk of low likelihood
but of high consequence. The system could prove to be
unstable once manufactured due to either uneven weight
distribution or insufficient material properties associated with
strength. If the machine was deemed unstable then it would be
unsuitable for use due to the safety risks which it would
present. This risk could be mitigated by adding reinforcements
to the structure in the form or additional struts and base panels
to manage the weight distribution more evenly.
Cannot meet cost target is a risk involved with all new
projects. The tight budget which we were allowed for our
project has required careful material and component selection.
The tight budget means that the likelihood of us failing to meet
our cost target is high, however, the consequences less severe.
Although ideally we would like to meet our cost target, the
consequence of not doing so has been rated as medium as
there are some simple steps which could be taken to mitigate
the risk. The supply chain could be reviewed and out sourced
materials and component reassessed to make it more lean.
Issues at Critical Design Review hold back project is a risk of
very high likelihood. The Critical Design Review is the last
formal stage before the project can go to manufacture and
therefore it is highly likely that problems will arise. If the Critical
Design Review takes place immediately before manufacture is
planned to begin then if issues do occur then progress will be
halted. The consequence of this happening is medium. It is not
disastrous for the project but will require modifications and
adjustments to be made quickly in order to then successfully
pass a second Critical Design Review and begin manufacture.
This risk can be mitigated by ensuring that the review takes
places well in advance of when manufacture is planned to start
in order to allow time for error and room for manoeuvre.
Competition introduces similar technology is a risk of both
medium likelihood and medium consequence. The risk of a
competitor in the market compromising the success of our
product by releasing their own similar model must be
considered. There is nothing which can be done to prevent such
an event occurring but if they were to sell their own technology
for a lesser price then it would have to be assessed whether we
could lower our own selling price in order to remain
competitive. A full report would have to be included within the
project evaluation.
Manufacture takes longer than predicted is a fairly likely
prospect, of medium likelihood and is a risk which would have
medium scale consequences. It can be difficult to accurately
estimate how long the manufacture of each part can take and
with so many parts to be manufactured within our project there
is a fairly large margin for error. To ensure that delays in
manufacture do not have severe knock on effects the time
allotted for manufacture for account for such delays i.e. allow
more time than is initially predicted.
Sourcing parts from overseas causes delays is something
which can be heavily accounted for and expected when
choosing to source parts from outside of the UK. There is a
moderate probability that there will be a delay due to the
distances travelled and as such a medium likelihood of the risk
occurring has been stated. The result of such a risk ranks at
medium in terms of severity as delays in the arrival in parts can
stop the whole project from remaining on track in terms of
time. In order to prevent this from happening it should be
ensured that all parts are ordered well in advance to allow time
for disruption.
Parts out of stock or delay in delivery is a risk of medium
likelihood and of medium consequence in terms of severity.
Suppliers may temporarily be out of stock and this will result in
a delay in receiving the item according to when they are able to
stock it again. In order to prevent this becoming an issue, all
orders must be placed with suppliers well in advance of when
they are required for use in manufacture and assembly.
Product not well received by consumers is a risk which
threatens the overall success of the project. If the benefits of
the system are not fully understood by the consumer and they
do not realise the advantages of our new resistance method
then this will have obvious detrimental effects on our products
success resulting in medium level consequences. This risk
occurring would be a result of insufficient marketing and
therefore in order to mitigate it both the methods of marketing
and the way in which the product is presented would need to
be improved.
Market proves too small is a risk associated with the size of
the market which we are entering into and this market not
being big enough to sell enough of our own product. The main
issue here is that cost would not be able to be recovered. As a
result of our prior market research the likelihood of this
occurring is low however the consequence is medium. In order
to mitigate this risk if it were to occur, the possibility of
extending our product into the market of home users could be
explored.
System not user friendly is a risk of only low likelihood. This is
a risk which must be considered yet which is unlikely to
materialise due to our research and concentrated efforts into
the user friendly nature of the machine. If the system does
however not prove to be user friendly i.e. is not easily
understood by the user, then this contradicts one of our largest
selling points and therefore has medium level severity
consequences. If this is this case then the whole interface of
the machine would need to be redesigned according to further
consumer research in order to improve the interactivity and
user friendliness of the machine.
 In response to our product, competitors reduce their own
selling price is a risk which could arise as we enter a market
where there are similar technologies available. If, upon entering
the market, other companies feel threatened by our product,
then they may reduce the selling price of their own product in
order to maintain business. The likelihood of this risk occurring
is relatively low but due to the actions we would need to take in
order to mitigate it, the level of consequences which would
result is medium. We would need to increase the marketing of
our own product and as a secondary measure also consider the
possibility of reducing the selling cost of own product in order
to remain competitive.
System fails to cater for 5th to 95th percentile is a risk which
would require a system redesign if it was to occur. Although the
likelihood of this risk is low, the medium level consequences are
a result of the redesign process which the risk mitigation would
entail. Not catering for those between the stated percentiles
means that for example, even a user with an arm reach
between those which the machine is designed for, is unable to
exercise efficiently on the machine.
Non-linear relationship between linear actuator position and
brake torque is a risk associated with how easy it is to
implement the control system. The risk would involve the
system not providing us with as accurate a braking force as we
require, we would be unable to quantify the accuracy of the
force. The likelihood of this risk occurring is medium but the
consequence is low. In order to mitigate this risk a more
complex feedback loop and more complex algorithm would
have to be implemented.
Material supplier closes down is a risk of both low likelihood
and low consequence. If a material supplier closes down then
for whichever of the components we sourced from them we
would need to find a new supplier.
Product overweight is a risk which must be taken into high
consideration for several reasons. If the system is over the
anticipated weight then this will have repercussions as far as
both transportation and assembly are concerned. Also, if the
system is too heavy in certain areas then the support structure
of the whole machine may be compromised. The likelihood of
this risk occurring is low, as are the consequences which would
result. In order to mitigate this risk materials would need to be
changed and the design could also be altered in order to
incorporate weight saving measures.

All of the elements of both sections of this risk assessment can

be easily displayed in table format as shown below. Each stage
of the assessment is included; the Initial Risk Assessment, the
Prioritised Risk Assessment and the Risk Mitigation.