As a plant manager, you are at the sharp end of PUWER compliance. You are responsible for the equipment, the people who use it, and the systems that keep both safe. You need a practical, systematic approach to PUWER risk assessment — one that ensures nothing is missed and that your assessments will withstand regulatory scrutiny.
This checklist is designed to give you exactly that. It covers the key areas that a PUWER risk assessment must address, structured as a practical tool you can use to audit your current arrangements and identify areas that need attention.
Equipment Inventory and Suitability
Do you have a complete, current inventory of all work equipment on site? Does each item have a unique identifier? For each piece of equipment, have you confirmed that it is suitable for its intended purpose, the environment in which it is used, and the people who operate it? Is all equipment correctly marked with CE or UKCA markings where applicable? For older equipment (pre-1995), have you assessed compliance against current safety standards?
Guarding and Protective Devices
Are all dangerous parts of machinery adequately guarded? Are fixed guards securely in place and not easily removable without tools? Where interlocked guards are used, do the interlocking mechanisms function correctly? Are interlocks tested at regular intervals, and are tests documented? Are guards appropriate for the specific hazards present? Are there procedures for working with guards removed (e.g., during maintenance or cleaning), and do these procedures provide adequate alternative protection?
Controls and Emergency Stops
Are all controls clearly identified and positioned to minimise risk? Are start controls designed to prevent unintentional operation? Do stop controls bring the machine to a safe stop? Are emergency stop devices easily accessible from all operating positions? Are emergency stops tested regularly, and are tests documented? Are all emergency stops clearly visible and marked? Is there a means of isolating the equipment from all energy sources?
Maintenance and Condition
Is there a documented maintenance programme for all work equipment? Are maintenance activities carried out at intervals based on risk assessment and manufacturer recommendations? Are maintenance records kept and accessible? Is equipment in good condition with no visible deterioration, damage, or wear that could present a risk? Are maintenance activities carried out by competent persons? Is there a procedure for reporting and addressing defects?
Inspections
Are inspections carried out at suitable intervals in accordance with Regulation 6? Are inspections performed by competent persons? Are inspection records maintained, including details of findings and any actions taken? Where inspections identify issues, is there a process for ensuring timely resolution?
Training and Information
Have all operators received adequate training on the specific equipment they use? Is training documented, including the content covered, dates, and evidence of competence assessment? Are operators provided with adequate information about the risks associated with the equipment and the safety measures in place? Is refresher training provided at appropriate intervals? Are there restrictions on equipment use to ensure only trained and authorised personnel operate specific machines?
Risk Assessments
Has a PUWER risk assessment been carried out for every piece of work equipment? Does each assessment identify all significant hazards, including those arising during normal operation, setting, maintenance, cleaning, and foreseeable misuse? Are control measures clearly documented? Are risk assessments reviewed regularly and updated when circumstances change? Are risk assessments carried out or reviewed by competent persons?
Turning This Checklist Into Action
If you have answered “no” or “not sure” to any of these questions, you have identified a compliance gap that needs addressing. The priority should be to tackle the gaps that present the highest risk first — particularly those relating to guarding, emergency stops, and isolation, as these are the areas most likely to cause serious injury and attract HSE enforcement.
Safety Management Ltd can help you work through this checklist systematically. We carry out comprehensive PUWER audits that assess every element of your compliance, identify gaps, and provide prioritised, practical recommendations. Our reports give you a clear roadmap for achieving and maintaining full PUWER compliance.
