Machinery & Industrial Equipment EHS & Safety Management Software

Manage safety across fabrication, machine assembly, equipment testing, commissioning, and field service.

Machinery manufacturers face changing hazards as individual components become powered, interconnected systems. A machine under construction may move through welding, machining, heavy assembly, electrical installation, pressure testing, and trial operation before shipment.

Dexur EHS connects workplace hazards, inspection findings, incidents, investigations, and corrective actions to the equipment, work order, and project stage involved. Help engineering, production, maintenance, and service teams coordinate safety follow-up as machine configurations and operating conditions change.

Maintain visibility across the factory floor, test bays, installation projects, and customer-site service activities.

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From report to resolution

Manage Safety as Equipment Moves From Assembly to Operation

Machinery manufacturing involves more than operating established production equipment. Employees also build, modify, troubleshoot, and test machines whose final safeguards or operating arrangements may still be under development.

A partially assembled hydraulic system can contain stored pressure. A control-panel test can introduce electrical exposure. A suspended gearbox can shift during alignment. A software or wiring change can alter how an actuator responds during commissioning.

Safety controls need to reflect the machine’s actual configuration and the task being performed.

Identify Hazards at Each Build Stage

Key concerns include:

Crushing and pinch points while aligning frames, shafts, cylinders, and mechanical assemblies
Suspended loads during movement of castings, motors, gearboxes, and machine bases
Unexpected motion during initial energization, troubleshooting, and functional testing
Stored hydraulic, pneumatic, spring, gravitational, and electrical energy
Pressure releases, hose failures, and fluid-injection injuries
Electrical contact and arc-flash hazards during panel work and troubleshooting
Entanglement and ejected material during machining or rotating-equipment tests
Welding fumes, grinding particles, hot surfaces, and fire hazards
Sharp edges and unstable components during fabrication and fit-up
Difficult access and awkward postures inside machine frames
Robot or automated-axis movement during programming and integration
Changing site conditions during installation and field service

Follow the Machine’s Changing Safety Conditions

Organize findings around the equipment lifecycle:

Fabrication → Mechanical Assembly → Electrical Integration → Testing → Shipment → Installation → Service

Within each stage, connect the action workflow:

01

Identify
02

Investigate
03

Prioritize
04

Assign
05

Correct
06

Verify

Record the relevant machine identifier, project, configuration, task, energy state, and responsible team.

For example, a near miss during actuator testing may require changes to the test procedure, exclusion zone, control logic, or physical restraint. The follow-up should establish whether the correction applies only to that machine or also to other builds using the same arrangement.

One unified platform

Coordinate Safety Across Machine Building and Service Operations

01 / INCIDENTS

Incident & Near-Miss Management

Document events involving fabrication equipment, machines under construction, test setups, lifting activities, and customer-site work.

Distinguish between the production equipment used to build a machine and the machine being manufactured or serviced. This helps investigators identify the correct asset, engineering owner, and affected projects.

Machinery-specific use cases include:

A cylinder moving unexpectedly during first energization
A suspended assembly shifting during alignment
A pressure-test hose or fitting failing
A tool or workpiece being ejected during trial operation
A technician encountering an undocumented energy source
A service engineer exposed to unexpected movement at a customer site

02 / INSPECTIONS

Inspections & Hazard Management

Structure inspections around the build stage and work activity.

Inspection topics can include:

Stability of partially assembled frames and components
Lifting arrangements, rigging condition, and load-control measures
Guards and access restrictions around operating machinery
Isolation points and means of controlling stored energy
Temporary wiring and electrical test arrangements
Hydraulic and pneumatic test connections
Welding, grinding, and compressed-gas storage conditions
Test-bay barriers, access controls, and emergency arrangements
Safe access for installation and maintenance tasks

Connect each finding to the relevant equipment or project so unresolved issues remain visible as work transfers between teams.

03 / COMPLIANCE

Compliance & Safety Records

Organize workplace safety records around applicable OSHA requirements and the activities conducted at the facility or customer location.

Connect:

Machine-guarding assessments
Hazardous-energy procedures and inspection records
Crane, hoist, and sling inspection findings
Electrical safe-work documentation
Welding and cutting precautions
Exposure assessments and protective measures
Training and qualification records
Incident investigations and injury records
Contractor coordination documentation

Keep workplace safety records identifiable alongside engineering documents, customer acceptance records, and product-safety assessments.

04 / CORRECTIVE ACTIONS

Corrective Action Management

Assign corrective work to the team able to address the cause.

Examples include:

Adding a mechanical restraint for a gravity-loaded assembly
Revising the isolation procedure for a hydraulic accumulator
Redesigning a fixture that allows a component to rotate during assembly
Correcting an electrical enclosure or exposed connection
Revising a pressure-test setup
Improving access for adjustment or lubrication
Addressing an unsafe troubleshooting method
Reviewing similar machines for the same hazard

Finding → Affected Equipment → Responsible Team → Required Change → Verification → Closure

Retain the connection between the original issue, approved correction, and evidence that the correction was checked.

Machinery Incident Reporting, Compliance & Technical Follow-Up

Capture Events Across Fabrication, Testing, and Service

Relevant incident and near-miss categories include:

Crush injuries during component positioning or fit-up
Dropped, swinging, or shifting loads
Rigging failures and lifting near misses
Contact with rotating shafts, couplings, chucks, and cutting tools
Ejected workpieces, tools, fragments, or test components
Unexpected movement during programming or functional testing
Hydraulic injection injuries and pressure-release events
Uncontrolled descent of raised machine sections
Electrical shock, arc-flash events, and unexpected energization
Welding burns, eye injuries, and fume exposure
Grinding-wheel failures and flying particles
Cuts from unfinished edges and fabricated parts
Manual-handling and awkward-access injuries
Falls while accessing large equipment
Customer-site installation and service incidents

Capture the Machine Configuration Behind the Event

An equipment name alone may not explain the conditions present during a machinery incident.

Record:

Project, work order, and machine serial number
Production asset or machine-under-build identification
Build, test, installation, or service stage
Task and personnel involved
Mechanical, electrical, hydraulic, and pneumatic configuration
Available energy sources and isolation status
Guarding and access conditions
Temporary connections or test arrangements
Relevant drawing, procedure, or control revision
Load weight and lifting arrangement where applicable
Pressure, speed, or other relevant test conditions
Immediate response and temporary restrictions
Photographs, statements, and supporting technical documents

Connect the investigation to the configuration in place at the time, particularly when subsequent work changes the equipment.

Investigate Technical and Organizational Causes

Event → Configuration Review → Task and Energy Review → Contributing Causes → Corrective Work → Verification → Closure

Investigations may need to examine:

Whether all energy sources were identified
Whether a temporary test arrangement introduced an uncontrolled hazard
Whether the procedure matched the actual machine
Whether a component was adequately supported
Whether a change was communicated to the next team
Whether the task required access inside a hazardous area
Whether engineering assumptions matched installation conditions
Whether similar equipment could present the same problem

A correction may require an engineering change, a safer work method, improved tooling, or a revised commissioning sequence.

Match OSHA Requirements to the Work Performed

Requirement	Machinery & Industrial Equipment application	Records and follow-up
General Machine Guarding — 29 CFR 1910.212	Point-of-operation hazards, rotating parts, nip points, and other hazards on machinery used in the workplace.	Guarding assessments, inspection findings, assigned corrections, and verification.
Mechanical Power-Transmission Apparatus — 29 CFR 1910.219	Exposed belts, pulleys, shafts, couplings, and other covered transmission components.	Component-specific findings and safeguarding corrections.
Control of Hazardous Energy — 29 CFR 1910.147	Covered servicing and maintenance involving unexpected startup or release of stored energy.	Equipment-specific procedures, employee training, periodic inspections, and energy-control findings.
Electrical Safe Work Practices — 29 CFR 1910.333	Electrical installation, servicing, and troubleshooting activities involving potential exposure to electrical hazards.	Work planning, deenergization and verification documentation, and applicable protective measures.
Overhead and Gantry Cranes — 29 CFR 1910.179	Covered cranes used to move machine frames, castings, motors, and assemblies.	Inspection records where required, defects, maintenance follow-up, and corrective actions.
Slings — 29 CFR 1910.184	Slings used in lifting and positioning components.	Inspection findings, damaged-equipment removal, and replacement actions.
Welding, Cutting, and Brazing — 29 CFR 1910 Subpart Q	Fabrication, repair, and installation work involving welding and cutting.	Fire precautions, ventilation assessments, protective measures, and work-area findings.
Abrasive Wheel Machinery — 29 CFR 1910.215	Covered grinding equipment used in fabrication and finishing.	Guarding and equipment-condition inspections and follow-up.
Hazard Communication — 29 CFR 1910.1200	Exposure to hazardous coatings, solvents, cleaners, metalworking products, and other chemicals.	Chemical inventories, safety data sheets, labeling, and training.
Occupational Noise Exposure — 29 CFR 1910.95	Noise associated with machining, fabrication, grinding, and equipment testing.	Exposure assessments and hearing-conservation records where required.
Injury and Illness Recordkeeping — 29 CFR Part 1904	Covered occupational injury and illness recording and reporting.	Recordability reviews, applicable OSHA forms, and supporting incident information.

Requirements depend on the machinery and activity involved. OSHA provides separate provisions for particular machine types; one machine-specific standard should not be applied indiscriminately to all presses or production equipment. OSHA: Machinery and Machine Guarding, Materials Handling and Storage

Treat Testing and Positioning as a Defined Safety Activity

Some work requires temporary energization to test or position equipment. Under 29 CFR 1910.147(f)(1), covered situations require a defined sequence for clearing equipment and personnel, removing energy-control devices, testing or positioning, and then deenergizing and reapplying energy controls before servicing continues.

Record the task, responsible personnel, access arrangements, and return to the controlled servicing condition. A “test mode” label alone does not resolve hazardous-energy obligations. OSHA: Control of Hazardous Energy

Evaluate Electrical Troubleshooting Separately

Electrical troubleshooting can present hazards beyond unexpected machine movement. OSHA’s electrical work-practice requirements address deenergization and the conditions under which work on energized parts may be performed.

Connect the electrical work assessment with the machine’s energy-control arrangements and the qualifications of personnel performing the task. OSHA: Electrical Safe Work Practices

Distinguish Workplace Compliance From Machinery Design Requirements

Machinery manufacturers manage both employee safety and the safety requirements associated with the equipment they supply.

Requirement category	Primary purpose	Relationship to EHS records
OSHA workplace requirements	Protect employees performing manufacturing, testing, servicing, and installation work.	Document workplace hazards, work practices, incidents, inspections, and corrective actions.
Machinery design and risk-assessment standards	Guide identification and reduction of hazards associated with machine design and intended use.	Link relevant design findings to workplace events and engineering follow-up.
Customer specifications and acceptance requirements	Establish contractual expectations for the delivered equipment.	Reference applicable acceptance findings and responsible technical owners.
Destination-market product requirements	Establish requirements for placing machinery on a particular market.	Coordinate with the responsible product-compliance team and retain references to its determinations.
Environmental permits and waste requirements	Govern applicable emissions, discharges, waste handling, and releases from manufacturing activities.	Track facility-specific tasks, findings, and corrective work.

ISO 12100, for example, addresses machinery risk assessment and risk reduction. It serves a different purpose from an OSHA workplace inspection. Applicable consensus standards, customer requirements, and destination-market obligations should be determined for the specific equipment. ISO: Safety of Machinery—Risk Assessment and Risk Reduction

For robotic systems, risk assessment must consider integration and tasks such as programming, setup, maintenance, and troubleshooting. OSHA’s technical guidance discusses these activities and relevant safeguarding considerations. OSHA: Industrial Robot Systems and Industrial Robot System Safety

Dexur’s EHS records can support this coordination while engineering and product-compliance teams retain responsibility for technical validation and conformity decisions.

Generate Reports That Identify Equipment-Specific Problems

Useful reports include:

Incidents by build stage, machine family, and task
Unresolved guarding and energy-control findings
Lifting events by component and handling arrangement
Pressure-test and commissioning near misses
Recurring issues associated with a shared design or fixture
Open actions affecting upcoming test activities
Field-service findings awaiting engineering review
Corrective actions requiring application to other machines
Repeat findings after equipment modifications

Identify Risk Before the Next Energization, Lift, or Test

Machinery safety priorities often depend on the next planned activity.

An incomplete guard may become critical before trial operation. A lifting concern must be resolved before moving an assembly. An undocumented energy source may affect every technician who services the machine.

Review findings against the upcoming work and the people who could be exposed.

Ask Questions That Reflect Machine-Building Operations

Which machines have unresolved hazards before first energization?
Which assemblies lack a verified lifting or restraint arrangement?
Are temporary test connections remaining in use longer than planned?
Which machines have isolation procedures that no longer match their configuration?
Are repeated commissioning events linked to the same actuator or control arrangement?
Which service findings suggest a problem across a machine family?
Have changes to guarding or controls been reviewed for new hazards?
Which actions require verification before testing resumes?

Prioritize by Consequence and Planned Exposure

Review potential severity, likelihood, exposure, and the reliability of existing controls.

Include conditions with serious consequences even when no injury has occurred, such as uncontrolled motion, falling assemblies, high-pressure releases, and electrical exposure.

Build-Stage Findings + Test Events + Inspection Results + Service Feedback + Engineering Changes

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Identify Affected Machines and Tasks

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Prioritize Before the Next Exposure

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Assign Technical and Operational Corrections

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Verify Against the Actual Configuration

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Review Other Affected Equipment

Measure Safety Across Fabrication, Commissioning, and Service

Use measures that show both injury outcomes and the condition of controls before high-risk work begins.

KPI	What to measure	Machinery & Industrial Equipment application
OSHA TRIR and DART Rate	Recordable cases and cases involving days away, restricted work, or job transfer, normalized by hours worked.	Review factory and field-service outcomes with appropriate task and exposure context.
Pre-Test Safety Review Completion	Planned reviews completed before first energization or defined test milestones.	Identify machines entering test activities with incomplete safety follow-up.
Open Critical Guarding and Energy-Control Findings	Number, age, affected equipment, and interim-control status of serious findings.	Highlight unresolved motion, access, and stored-energy hazards.
Lifting and Load-Control Events	Incidents and near misses involving cranes, rigging, component movement, and assembly stability.	Identify recurring difficulties with particular components, fixtures, or handling methods.
Commissioning and Pressure-Test Near Misses	Events by test type, machine family, and configuration.	Detect patterns involving unexpected motion, pressure release, and temporary setups.
Verified Corrective Action Performance	On-time verified closure, overdue work, and recurrence after closure.	Determine whether engineering and operational corrections were completed and checked before the next relevant activity.
Field-Service Findings Requiring Engineering Review	Findings awaiting assessment, review time, and affected machine population.	Track whether customer-site lessons reach the teams responsible for design and service procedures.

Interpret near-miss reporting alongside participation and work volume. More reports can indicate improved visibility rather than worsening conditions.

Give Each Team the Safety Information Relevant to Its Work

Corporate EHS Leaders

Compare conditions across manufacturing plants, integration facilities, test centers, and service operations.

Review:

Significant incidents and high-potential near misses
Recurring hazards across machine families
Guarding and energy-control action status
Lifting and commissioning trends
Contractor and field-service findings
Corrective actions requiring broader application
Differences between fabrication, assembly, and service exposure

Plant Managers and EHS Managers

Monitor active work and the hazards associated with upcoming activities.

Track:

Machines approaching test milestones
High-risk assembly and lifting work
Open equipment and work-area findings
Unresolved energy-control issues
Overdue engineering and maintenance actions
Exposure-assessment follow-up
Contractor installation activities
Environmental findings from manufacturing processes

Engineering and Commissioning Leads

Review findings tied to the machine’s configuration, test plan, and proposed changes.

Identify actions requiring technical assessment, revised drawings, altered test arrangements, or verification before work proceeds.

Assembly Supervisors and Field-Service Leads

See task-specific findings, temporary restrictions, assigned corrections, and handover information.

Ensure the next team has access to unresolved issues when machinery moves from mechanical assembly to electrical integration, from testing to shipment, or from installation to service.

Follow the Equipment and Organizational Hierarchy

Organization

Enterprise
Facility / Customer Site
Department / Project

Operations

Machine / Serial Number
Build or Service Stage

Follow-Through

Finding / Incident
Corrective Action

This structure connects management reporting to the physical equipment and work behind each record.

Keep the Safety History Connected as the Machine Changes

A machinery safety issue may begin in assembly, require an engineering correction, appear again during testing, and influence a later service procedure.

A connected EHS record preserves that history as responsibility moves between teams and locations.

Preserve Configuration and Task Context

Record which machine, revision, energy condition, and activity were involved. Help investigators distinguish hazards on production equipment from hazards on the machine being built.

Connect Findings to Engineering Follow-Up

Route design-related concerns to the responsible technical team. Maintain visibility into whether the correction affects one unit, a shared component, or an entire machine family.

Make Unresolved Work Visible Before High-Risk Activities

Review outstanding findings before lifting, energization, pressure testing, commissioning, and service work. Associate deadlines with the relevant work milestone.

Strengthen Energy-Control and Guarding Records

Connect procedures, inspections, changes, and corrective actions to the equipment they address. Identify when the documented arrangement no longer matches the machine.

Coordinate Factory and Customer-Site Responsibilities

Maintain a consistent record of installation and service findings while documenting host-employer interfaces, contractor responsibilities, and site-specific conditions.

Verify Corrections Against the Equipment

Support closure with evidence of the completed change and an appropriate verification record. Distinguish completion of a task from confirmation that the identified hazard was addressed.

Apply Lessons Across Similar Machines

Use recurring findings and service feedback to identify other equipment requiring review. Track the follow-up beyond the original incident or project.

See Dexur EHS for Machinery & Industrial Equipment

Connect fabrication hazards, assembly findings, equipment testing, commissioning events, service feedback, and corrective actions across your machinery operations.

See how Dexur EHS can help your teams maintain safety visibility from the first assembly operation through installation and field service.