Industrial Robot Risk Assessment Template ISO 10218
A comprehensive risk assessment template for industrial robot operations compliant with ISO 10218-1 and ISO 10218-2. Used by safety engineers and robot technicians to identify hazards, assess risks, and implement protective measures for robot cells and collaborative applications.
This risk assessment template is designed for industrial robot systems operating under ISO 10218-1 (robot) and ISO 10218-2 (robot system and integration). It documents a systematic review of all foreseeable hazards — including crushing, trapping, ejection, and collaborative mode risks — and prescribes protective measures such as safeguarding zones, speed limits, and force/torque limits. This template supports the risk assessment process required by ISO 12100 and ANSI/RIA R15.06 for robot cell commissioning and recertification.
- Crush / pinch points — identify all locations where the robot arm, end-effector, or moving load can trap a person against a fixed structure. Verify that safeguarding devices (light curtains, safety mats, interlocked gates) cover these zones per ISO 10218-2:2011 §5.3.
- All personnel entering the safeguarded space must wear impact-rated safety glasses, steel-toed boots, and fitted clothing with no dangling jewelry or loose sleeves. For collaborative applications, torque-limiting tools and force-limited grippers must be verified at each shift start.
- Lockout / tagout (LOTO) must be applied to the robot controller, servo drives, and any pneumatic/hydraulic supplies before any manual intervention inside the cell. Verify zero-energy state with a qualified electrician.
- For collaborative operations, confirm that robot TCP speed does not exceed 250 mm/s per ISO 10218-1:2011 §5.10.5 and that the measured force at any pinch point is below 150 N.
Risk Assessment Matrix — Robot Cell Hazards
| Status (P/F) | Checklist Item / Hazard | Compliance Standard | Action Required / Notes |
|---|---|---|---|
| [ ] Pass [ ] Fail | Robot mounting base secure — all bolts torqued to manufacturer specification | ISO 10218-2 §5.2 | _________________ |
| [ ] Pass [ ] Fail | Safeguarded zone defined — light curtain height/distance compliant with stopping time calculations | ISO 10218-2 §5.3.2 | _________________ |
| [ ] Pass [ ] Fail | E-stop function tested — all four circuits (robot controller, cell panel, pendants, remote) interrupt motion within 200 ms | ISO 10218-1 §5.3.2 | _________________ |
| [ ] Pass [ ] Fail | Collaborative speed limit verified — TCP ≤ 250 mm/s in shared workspace | ISO 10218-1 §5.10.5 | _________________ |
| [ ] Pass [ ] Fail | Force / torque limiting — gripper force ≤ 150 N at any pinch point | ISO 10218-1 §5.10.4 | _________________ |
| [ ] Pass [ ] Fail | End-effector tooling — no sharp edges, all fasteners secured with thread-locker | ISO 10218-2 §5.5 | _________________ |
Incident / Corrective Action Log
| Date / Time | Item # | Safety Issue Identified | Corrective Action Taken | Assigned To |
|---|---|---|---|---|
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
| ___/___/_____ | _______ | _______________________________ | _______________________________ | _______ |
By signing below, the supervisor or designated competent person verifies that all risk assessment checks, safeguarding device tests, and collaborative mode verifications have been completed according to ISO 10218 and internal safety policy. Any non‑conformities identified above have been documented and corrected.