Kestrel Process Group

Asset Integrity — equipment safety assessment

HP/GM-105

Bagging machine 105

Report A-1063

Methodology v4.0

2025-10-28

Assessed risk

Critical

Highest score

Findings

Immediate

Coverage

16/16

Next due

2026-10-28

Stop use, isolate, escalate to the responsible engineer

Asset class

Guarded machinery / conveyor

Facility

Havenport Terminal, Dock Road

Area

Packing hall

Criticality

Manufacturer

Preston Automation

Model / serial

P362 / 50075-94

Installed

2007-06-01

Inspector

R. Aldridge

Findings (5)

R-GM-01Fixed guard missingImmediate dangerphotographic evidenceS5 × L4 = 20Critical

A fixed guard is absent and the hazard it covered is reachable during normal operation.

Action Stop the machine and lock it out until the guard is refitted with tools-required fixings.

Entanglement or crushing at moving parts · due 2025-10-28 · AS 4024.1601 §5.2 · evidence VC-MISSING-GUARD

R-GM-06Emergency stop out of reachNon-conformingS4 × L3 = 12High

An operator cannot reach an emergency stop from every working position.

Action Add stops or a pull-cord run so no working position is more than the methodology's distance from one.

Entanglement or crushing at moving parts · due 2025-11-11 · AS 4024.1601 §5.5

R-GM-10Stored energy sources not documentedRecords / traceabilityS3 × L3 = 9Moderate

Stored energy is not documented, so isolation cannot be verified as complete.

Action Walk the machine with the maintainer, list every energy source, and publish it at the isolation point.

Loss of design or inspection traceability · due 2025-11-27 · ISO 14118 §6

R-GM-15Spillage or accumulation around the machineObservationphotographic evidenceS2 × L4 = 8Moderate

Accumulated product or spillage is a slip hazard and hides developing faults.

Action Clean down and add the area to the shift housekeeping round.

Access, egress and emergency response impaired · due 2025-11-11 · ISO 12100 §6.2.7 · evidence VC-HOUSEKEEPING

R-GM-17Leak or product loss at the machineObservationphotographic evidenceS2 × L3 = 6Moderate

Fluid loss is visible at a gland, gearbox or hydraulic joint.

Action Repair the leak and clean the area so the next assessment can distinguish new loss from old.

Loss of containment to environment · due 2025-11-27 · ISO 12100 §6.2.7 · evidence VC-LEAK

Photographic record

Site photograph taken at assessment

Illustration of a conveyor drive end with an open gearbox/belt-and-pulley drive on a green frame at left, a yellow mesh guard panel mid-span, an E-stop pull-cord with red button along the top, and a brown fluid pool on the floor beneath the drive.

Leak, drip or product staining — A brown/amber pool with scattered droplets sits under the drive, with a dark line running down from the underside of the blue gearbox/motor into the pool.
Guard removed or rotating part exposed — Drive pulleys, belt and gear wheel are fully visible in the open within a black-backed frame with bolt holes/fixings at each corner and along the edges, no cover panel fitted.
Housekeeping around the asset — Spilled liquid pool roughly 1 m across with scattered droplet spatter spreading across the floor slab.

Assisted by claude-opus-5; every observation adjudicated by the inspector before use.

Assessment record

Identification and records · Is a current risk assessment on file for this machine?Yes

Identification and records · Is the manufacturer's manual available on site?Yes

Identification and records · Has the machine been modified since commissioning?No

Guarding · Are all fixed guards present and secured with tools-required fixings?Yes

Guarding · Are movable guards interlocked?Yes

Guarding · Is any interlock bypassed, taped or defeated?No

Guarding · Are in-running nips and drives guarded?Yes

Guarding · Largest gap in guarding16 mm

Emergency stop and isolation · Furthest distance from any operating position to an emergency stop4.5 m

Emergency stop and isolation · Does the pull-cord stop the machine from every point along its run?Yes

Emergency stop and isolation · Does restart require a deliberate reset at the machine?Yes

Emergency stop and isolation · Is the isolation / lockout point identified and lockable?Yes

Emergency stop and isolation · Are all stored energy sources documented for isolation?No

Workplace · Is hazard and isolation signage in place?Yes

Workplace · Clear walkway width alongside the machine954 mm

Workplace · Housekeeping around the machineClean

The PDF is generated server-side from this same data — same findings, same wording, same methodology version, plus the photo plate and a sign-off block.