The installation of industrial machinery is a complex process that requires not only technical knowledge, but also knowledge of the applicable regulations. The correct installation of industrial machinery, on the other hand, is not only a technical issue, but above all an organisational and legal one. Standards for the assembly of machinery in industry and relevant regulations are essential for equipment to operate safely, legally and as intended. Ignoring formal requirements can result in serious consequences. Fines, production downtime and real health risks for workers are just some of them.
Below you will find a practical study to help you understand, what standards apply to the assembly of machineryThe following information is available on the website: what documents need to be prepared and what special attention should be paid. You are welcome!
What documents are required for the installation of machinery?
The relevant documents are not just a formality. They are proof that the machine has been installed in accordance with current legislation. They provide security for the employer and installers in the event of inspections, accidents or legal disputes. It is worth remembering that the absence of certain documents can result in financial penalties or even the immobilisation of the entire plant. What documents are required when installing machinery?
1. installation instructions from the manufacturer
This is a basic document that should accompany every machine. It contains a detailed description of the installation method, mechanical and electrical connections, as well as recommendations for the installation conditions (e.g. required substrate, ventilation, noise level).
In accordance with legal requirements for the installation of equipment, the instructions should be in the language of the end user and easy to understand by those installing the device.
2. the CE Declaration of Conformity
This confirms that the machine meets the requirements of EU directives - in particular Machinery Directive 2006/42/EC. This document must be provided by the manufacturer and include, inter alia:
- manufacturer's name,
- machine description,
- a list of the harmonised standards used,
- details of the person responsible for issuing the declaration.
The absence of this document makes it impossible to start the device legally. It is also essential for the process certification and safety assurance of installed equipment.
3 Risk assessment
In accordance with health and safety regulations for the assembly of machinery, a hazard assessment must be carried out before any new equipment is put into operation. This is a document that identifies potential hazards, assesses their likelihood and consequences and then identifies safety measures.
The risk assessment should be carried out by a trained professional and relate to the specific machine in its target working environment.
4 Technical file of the machine
It includes the complete technical data necessary for the operation, maintenance and servicing of the machine. The documentation includes, among other things:
- electrical, pneumatic and hydraulic diagrams,
- data on safety systems,
- list of spare parts,
- rules for connecting external devices.
It is an important part of the overall supervision of the equipment during its life cycle. It can be essential for processes such as disassembly or relocation of machinery.
5. technical acceptance protocol
Once the installation has been completed, it is necessary to check that the equipment has been installed in accordance with the requirements. The acceptance should be carried out by an authorised person (e.g. an engineer, technical manager or health and safety inspector).
The protocol includes information on:
- installation date,
- persons responsible for the installation,
- verification of the operation of individual machine functions,
- confirmation of compliance with standards and regulations.
Notification to technical supervision (if required)
Some machines are subject to additional regulations. Examples include pressure equipment, cranes or machinery with gas installations. They are then required to be notified to the Office of Technical Inspection or other regulatory body. As part of the legal requirements for the installation of equipment, such notifications are necessary to obtain permission to operate them.
7. Inspection and maintenance register
From the moment the machine is installed, records should be kept of all maintenance activities. This makes it possible to plan servicing, extend the life of the machine and meet inspection requirements.
This is an important part of the site's safety management system.
Technical acceptance and quality control after installation - how to pass inspection?
Once the installation of any industrial machine has been completed, technical acceptance and quality control must be carried out. This is a formal procedure to confirm that the machine has been installed in accordance with the design, technical documentation and current regulations. This is not only an organisational requirement, but also an obligation under the regulations governing the installation of machinery.
During acceptance, among other things, the following are checked:
- the completeness of the installation,
- compliance with the documentation provided by the manufacturer,
- correctness of electrical, hydraulic and pneumatic connections,
- operation of control and safety systems,
- whether standards for the assembly of machinery in the industry have been met.
Post-assembly quality control steps
1. Verification of documentation - all documents that should accompany the equipment are checked. These include: installation and operating instructions, CE declaration of conformity, risk assessment, certificates of components used, results of technical tests. The absence of any of these documents may result in a refusal of technical acceptance.
2. Verification of compliance with health and safety standards and regulations - This assesses whether the machine complies with specific safety standards and regulations to protect the health and lives of workers. Amongst other things, the availability and effectiveness of guards, the marking of danger zones, the correctness of emergency buttons and the ergonomics of operating the machine are assessed. Failure to comply with health and safety regulations when assembling machinery results in the need for corrections before the machine is put into operation.
3. Operational and functional tests - is to start up the machine and check that all systems are functioning correctly. The following are assessed: operation of drives, response to control signals, emergency stopping, interaction with other equipment in the production line, machine behaviour during overloads or simulated errors.
4. Assessment of the quality of physical assembly - The inspectors check, among other things, that the components are correctly fitted, that there are no loose connections, that the correct components and materials are used, and that any residues (e.g. chips, dust) have been removed after assembly. All these elements are particularly important if the machine is to operate reliably and safely.
Penalties and consequences resulting from non-compliance with assembly standards
Assembly of machinery in industry is a process that requires precision, experience and knowledge of the applicable regulations. While many companies focus on the technical side and lead times, equally important, and often overlooked, are the applicable legal regulations for the installation of machinery. Their disregard can lead to serious legal, financial and operational consequences.
Failure to comply with standards and regulations can result not only in fines, but also in production stoppages and, in extreme cases, even criminal liability. Below you will find an overview of the most common penalties and a practical explanation of why it makes sense to ensure compliance from the outset.
The most common administrative penalties:
1. financial fines
Technical supervisory authorities (e.g. PIP, UDT) have the right to impose fines on entrepreneurs who do not comply with the law. The amount of the fine depends on the scale of the infringement, the number of workers at risk and previous inspections.
2. stopping the use of the machine or the entire production line
In the case of serious irregularities, inspectors can suspend the use of a machine until the non-conformities are corrected. Such a decision can paralyse production for days or weeks, generating financial and reputational losses for the company.
This is often the case if the machine does not meet the safety requirements set out in EU standards or has not been installed correctly.
3. prohibition of operation of the device
If an appliance has been installed without a permit or has not passed technical acceptance, the technical supervision may issue a decision prohibiting its use. Such a ban remains in force until the required documents are provided and a re-inspection is carried out.
Criminal and civil liability
In situations where non-compliance with the standards leads to an accident or the creation of a risk to human health and life, liability may extend beyond administrative fines.
1. criminal liability of management
If an accident occurs as a result of incorrect installation of a machine, the management of the company or the person responsible for the installation may be criminally liable. This applies to situations where duties under safety regulations have been ignored or a non-compliant machine has been knowingly put into operation. Under the Criminal Code, this is punishable by a fine, restriction of freedom and, in extreme cases, even imprisonment.
2. civil actions from employees
If a worker's health is injured as a result of negligence in the installation, he or she can claim compensation through the courts. It will then be necessary to show that all formal and technical obligations related to the installation of the machine were fulfilled. Lack of documentation, inadequate installation or failure to carry out a risk assessment are the most common causes of lost cases.
Risk of loss of certificates and concessions
Some companies, especially those operating in industries requiring special authorisations (e.g. chemicals, energy, food industry), can lose their operating licences if they fail to comply with technical standards. Errors in the assembly of machinery, non-compliance with EU directives or inadequate documentation can lead to the revocation of ISO certificates or the closure of a plant by the supervisory authorities.
