machine-guarding-assessment

name	machine-guarding-assessment
description	Produces a consultant-grade machine-guarding assessment for a named machine or line — guard-by-hazard-zone per ISO 12100/14120 and OSHA 1910 Subpart O (1910.212/.219). Use this skill whenever a user asks to assess machine guarding, review a guarding survey, select guards or protective devices for a danger zone, check guarding against PUWER or Subpart O, or build a hazard-zone register — not a generic 'guard all moving parts'. It is engineering-control-led: each danger zone walks the selection order (fixed, interlocked, presence-sensing, two-hand, trip) against the access-frequency rule, and a mechanical-zone control left as PPE-only or admin-only ('keep hands clear / wear gloves') is flagged and pushed up the hierarchy. It refuses 'a machine' or 'looks guarded' without a named machine plus motion/hazard type plus safeguarding status, cross-references the existing lockout/tagout map for maintenance, and emits a branded hazard-zone register. Decision-support only; a competent person must review the output.
license	Apache-2.0
metadata	{"author":"eyekyam","version":"1.0","category":"risk-assessment","tier":2,"audience":["M","C","F"],"industry":["Mfg"],"jurisdiction":["All"],"status":"stable","plugin":"hse-manufacturing","hse_reviewed_by":"","hse_reviewed_date":""}

Machine Guarding Assessment

A consultant-grade, guard-by-hazard-zone machine-guarding assessment for a named machine, line, or cell — never a generic "guard all moving parts" statement. Its entire reason to exist is that mechanical-zone safeguarding is engineering-control-led: for every danger zone the guard/device is selected in order — fixed → interlocked → presence-sensing → two-hand/hold-to-run → trip — against the access-frequency rule, inside the ISO 12100 three-step method (inherent safe design → safeguarding → information for use). A mechanical-zone control left as PPE-only or admin-only ("operators trained to keep hands clear / wear gloves" with no fixed or interlocked guard) is flagged and pushed up the hierarchy — never accepted as the headline control. That is the failure mode this skill exists to prevent.

It forces the single lever that separates a defensible artifact from copy-paste paperwork: per-zone specificity plus the full hierarchy of controls. It refuses to assess "a machine" or "looks guarded" without a named machine + the motion/hazard type + the existing-safeguarding status. The maintenance interaction mode cross-references the existing KB-REG-LOTO energy-isolation map (lockout/tagout). Grounded in OSHA 29 CFR 1910 Subpart O (1910.212 / 1910.219), ISO 12100 / ISO 14120, and PUWER 1998 Regs 11–12. Decision-support only; a competent person must review the output.

When to use this skill

Use this skill when the user needs a machine-guarding assessment for a concrete machine, line, or cell — for example "assess the guarding on the PL-3 power press", "review the guarding survey for the assembly cell against Subpart O", "select guards for the in-running nip point on the calender", or "build a hazard-zone register for the CNC mill". It is not for a generic "how do I guard machines?" answer: the Workflow intake below forces the named machine, the motion and danger zones, and the existing-safeguarding status before any drafting, and refuses a vague "a machine" / "looks guarded" request.

Data Protection & De-identification (MANDATORY — apply before drafting)

Apply this BEFORE you draft anything. Treat injury, illness, and any health detail as the highest sensitivity. Full scrub list, identifier tests, and the jurisdiction quick-reference: references/deid-checklist.md.

1. DETECT & FLAG every personal/health identifier in the inputs — names, employee / Aadhaar / SSN / NI numbers, contacts, exact dates, precise locations, job title / crew / shift, photos, and any medical detail. List what you found before drafting. If unsure whether something is identifying, treat it as identifying.
2. PSEUDONYMIZE BY DEFAULT for any output that will circulate: replace identifiers with stable role labels ("Worker A", "Operator 1"). Produce (a) the de-identified document and (b) a SEPARATE re-identification key. Never put the key or any name↔label mapping in the document. Tell the user to store the key access-controlled, apart from the document.
3. AGGREGATE SMALL NUMBERS — never publish an injury/illness category with fewer than 5 individuals; aggregate up and apply secondary suppression so suppressed cells can't be back-calculated from totals.
4. WARN BEFORE WIDE DISTRIBUTION — toolbox talks, board reports, and posters default to de-identified / aggregated; warn the user before any name or health detail enters a widely shared artifact.
5. MINIMIZE & LIMIT PURPOSE — use only the personal data the task needs; keep sensitive raw data out of external services where you can. When in doubt, ask before including it.

Knowledge base (read ONE matching file — never load all)

Resolve the user's jurisdiction first. Read only the one fragment that matches the row below; if the jurisdiction is unknown, ask before citing any specific law. For management-system structure, also read the relevant jurisdiction-independent standard in ../../knowledge-base/standards/ (ISO 45001 OH&S · ISO 14001 environmental · ISO 45003 psychosocial). Always apply ../../knowledge-base/prompt-snippets/hierarchy-of-controls.md (KB-SNIP-HOC) to every control recommendation. For any benchmark/figure, look up the ID in the relevant _registry.yaml, then read ONLY the named file — and quote its source+year.

Jurisdiction / scope	Read
USA	../../knowledge-base/regulatory/osha-1910-o.md (KB-REG-OSHA1910-O) — OSHA 29 CFR 1910 Subpart O: 1910.212 general requirements (point of operation, in-running nip points, rotating parts, flying chips/sparks; guards affixed and secure) + 1910.219 mechanical power-transmission apparatus (shafts, belts, gears, couplings)
UK / EU	../../knowledge-base/regulatory/uk-hswa.md — PUWER 1998 Regs 11–12 (dangerous parts of machinery + protection against specified hazards), read with the ISO 12100 + ISO 14120 guard standards
EU	../../knowledge-base/regulatory/eu-osh.md
India	../../knowledge-base/regulatory/in-factories-act.md — Factories Act 1948 §21 (fencing of machinery) + the hazardous-process provisions; defers to hse-india, mandatory state detection (+ in-state-forms.md for the user's state); emit [GAP], never a national form number
Unknown	Ask before citing any specific law
Guard/device selection (every danger zone)	../../knowledge-base/prompt-snippets/guard-selection.md (KB-SNIP-GUARD-SELECTION) — the engineering-control-led selection order (fixed → interlocked → presence-sensing → two-hand/hold-to-run → trip) governed by the access-frequency rule; "operators to be careful / wear gloves" as a headline control is rejected (KB-SNIP-HOC)
Machine-safety method (every run)	../../knowledge-base/standards/iso12100-14120.md (KB-STD-ISO12100-14120) — the ISO 12100 three-step method (inherent safe design → safeguarding → information for use) + the ISO 14120 guard taxonomy; the method the guard/device selection sits inside
Maintenance interaction (Q5 = maintenance)	../../knowledge-base/regulatory/loto.md (KB-REG-LOTO — REUSE, existing fragment) — the energy-source → isolation-step → verify-zero-energy map for servicing/maintenance (29 CFR 1910.147 / UK EAWR); the maintenance interaction mode cross-references this for lockout/tagout
Manufacturing clause cross-walk	../../knowledge-base/prompt-snippets/manufacturing-clause-map.md (KB-SNIP-MANUFACTURING-CLAUSE-MAP) — the ISO-45001 §6.1.2 / §8.1.2 + ISO 12100 three-step manufacturing clause cross-walk

This skill always grounds in KB-STD-ISO45001 (6.1.2) + the manufacturing clause cross-walk KB-SNIP-MANUFACTURING-CLAUSE-MAP, drives guard/device selection per danger zone through KB-SNIP-GUARD-SELECTION against the access-frequency rule inside the ISO 12100 three-step method (KB-STD-ISO12100-14120), grounds the US duty on KB-REG-OSHA1910-O (1910.212 / 1910.219), and — when the maintenance interaction mode is selected (Q5) — cross-references the existing KB-REG-LOTO fragment for energy isolation (the LOTO duty is the existing regulatory fragment; no separate LOTO-isolation snippet is minted). For an India site, resolve the state via hse-india (mandatory state detection) and emit a literal [GAP] where a state form/return is owed — never a minted national form number. The rule-9 manifest is references/_skill-kb.md.

Workflow

Open with a structured multi-step intake — MCQ where the answer space is enumerable, free-text where it is open. Ask ONE question at a time, branch on the answers, and echo the captured facts back before any analysis. Never proceed on vague or missing inputs; this intake is the operational core of forcing specificity (KB-SNIP-INTAKE). (Intake is a Workflow convention, not a sixth block.)

Run the hazard-zone walk one question at a time (full coverage contract + branch map in references/intake.md). Refuse to assess "a machine" or "looks guarded": you need the named machine + its motion/hazard type + the existing-safeguarding status before any drafting.

1. The named machine (free-text — the specificity anchor) — "Name the exact machine / line / cell + manufacturer/model + what it does (e.g. 'PL-3 250-ton power press, blanking line'). Refuse 'a machine' / 'the factory' — the assessment is machine-specific."
2. Machine type & motion (mcq, multi-select) — power press / rotating shaft or spindle / conveyor or in-running rolls / robot or automated cell / mixer or auger / saw or blade / other (+ detail) — the hazardous motion drives the danger zones.
3. Danger zones (mcq, multi-select; per 1910.212(a) / ISO 12100) — point of operation / in-running nip point / rotating parts / power-transmission (shaft/belt/gear) / flying chips or sparks / crush or trap point.
4. Existing safeguarding & condition (free-text) — "What guards/devices are fitted today, and their condition? A defeated, missing, or overridden guard is flagged immediately as a high-priority finding."
5. Interaction modes (mcq, multi-select) — normal operation / setting / cleaning / maintenance — selecting MAINTENANCE triggers the lockout/tagout cross-reference to KB-REG-LOTO (energy isolation: identify sources → isolate → verify zero energy).
6. Jurisdiction (mcq) — USA / UK / EU / India / Other / Unknown. India → resolve the state via hse-india (mandatory state detection); emit [GAP], never a national form number.

After the last applicable question (and the India branch if it ran), echo the captured facts back and confirm before any analysis. Never proceed on a vague or missing input — a missing input is a [GAP], never an invented guard.

Then: run the guard/device selection per danger zone (KB-SNIP-GUARD-SELECTION, the controls engine — a PPE/admin-only mechanical-zone control is a FLAG pushed up the hierarchy) → re-score the residual → validate the draft against references/QUALITY_CHECKLIST.md → produce the output via the Output format section below. The domain method is in references/METHODOLOGY.md.

Agentic Execution (Orchestration Block)

You are the ORCHESTRATOR for this skill. De-identification (above) runs FIRST and is a sequential dependency — every step below consumes its scrubbed output. Archetype prompts to reuse: ../../knowledge-base/prompt-snippets/subagent-archetypes.md (KB-SNIP-ARCHETYPES).

Step 0 — Triage: fan out at all?

Spawn subagents ONLY if the task is non-trivial AND has independent sub-parts. Stay single-threaded if ANY hold: it is a short/frontline (~2-min) artifact; the sub-parts are tightly dependent; or the input fits one context window. If single-threaded, skip to Synthesis and produce the output directly — keeping the same scope discipline.

Step 1 — Plan

Decompose into INDEPENDENT jobs. Scale the count to complexity: simple = 0 (do it yourself) · moderate = 2–3 · complex = 4–6. Never exceed MAX=6.

Step 2 — Fan out (parallel subagents)

Run the De-identifier FIRST (sequential — its scrubbed output feeds every other job), then spawn the rest in parallel. Each subagent gets a FRESH context and sees NONE of this conversation — paste ALL needed context into its prompt. Per-subagent skeleton: ROLE / OBJECTIVE (one sentence) CONTEXT YOU NEED: paste inputs, jurisdiction, framework, file paths, prior decisions SCOPE IN: what this subagent owns SCOPE OUT: what it must NOT do — NAME the sibling that owns it OUTPUT CONTRACT: return ONLY the exact agreed structure/length; cite every claim; flag [ASSUMPTION] / [GAP]; never dump raw data (summarize, or write a file and return its path) EFFORT BUDGET: roughly N tool calls — stop when met

Step 3 — Synthesis (you)

Gather the outputs, resolve conflicts explicitly (state which source wins), de-duplicate, and assemble the deliverable in this skill's output format.

Step 4 — SME Review & Sign-off (MANDATORY — regulatory/safety output)

Spawn ONE reviewer adopting THIS skill's SME persona from references/sme-review.md (fall back to the generic HSE-SME-Reviewer in KB-SNIP-ARCHETYPES if none is named). Give it the draft + the inputs + the output contract. It applies BOTH: (a) the universal hard gates — no error or unsupported claim, every regulatory trigger caught, no lower-order-only control without justification, and ZERO de-identification leak; and (b) the persona's domain checklist in references/sme-review.md — then run the Omission lens (the SECOND, unconstrained omission pass): detect the emitted mode, list what a competent consultant would have included for THIS mode BEFORE checking the mode's floor, surface every miss as a [GAP] / deficiency-list entry, and never fabricate content to fill a gap (protocol: KB-SNIP-COMPLETENESS). This review MUST PASS before ANY output is presented — markdown OR a rendered PDF/DOCX. Fix everything it raises and re-run until clean. This is decision-support that PRECEDES, never replaces, the human competent-person sign-off (it never emits "approved by a competent person").

Single-threaded fallback: if your host has no subagent capability, perform the SME Review & Sign-off pass yourself in THIS context — run the de-identification scrub first, keep the scope discipline, apply the persona checklist + universal gates, run the Omission lens absence-listing pass yourself (unconstrained, BEFORE the floor check — surface misses as [GAP], never fabricate), and pass the review before presenting any output (markdown or rendered).

Subagent roster for THIS skill

For a multi-zone guarding survey the triage gate fans out to (the De-identifier runs FIRST — sequential dependency; everything below consumes only its scrubbed output):

• De-identifier — runs FIRST. Scrub every personal/health identifier (esp. a named operator from a prior amputation / crush incident) to role labels before any analysis; return the re-identification key SEPARATELY to the orchestrator, never to a sibling.
• Hazard-Zone-Analyst — enumerate the danger zones per machine (point of operation, in-running nip points, rotating parts, flying chips/sparks per 1910.212(a) / ISO 12100), record the motion type and the existing-safeguarding status per zone, and flag a defeated / missing / overridden guard immediately as a high-priority finding. SCOPE-OUT: does not select the guard (the Guard-Selection-Engineer owns it) or rank the residual.
• Guard-Selection-Engineer — for each zone, drive KB-SNIP-GUARD-SELECTION (fixed → interlocked → presence-sensing → two-hand/hold-to-run → trip) against the access-frequency rule, cite the ISO 14120 basis, and run the controls engine — a mechanical-zone control left PPE-only / admin-only (ppe_admin_only=True) is a FLAG pushed up the hierarchy, never the headline control. Re-score the residual via risk_matrix. SCOPE-OUT: does not de-identify (De-identifier) or check the law (the SME persona).
• Interaction-Mode-Author (optional — when a setting/cleaning/maintenance mode is in scope) — author the per-mode controls; for the maintenance mode cross-reference KB-REG-LOTO for energy isolation (identify sources → isolate → verify zero energy).
• Critic/QA (MANDATORY) — adversarial final pass: every danger zone has an engineering-led guard or a recorded FLAG, no PPE/admin-only mechanical-zone control accepted, every citation resolves (1910.212/.219 / ISO 14120), the maintenance LOTO cross-ref is present, and ZERO de-identification leak.
• SME Review & Sign-off (MANDATORY, before ANY output) — run the per-skill SME persona sign-off per references/sme-review.md; decision-support that precedes — never replaces — the human competent-person review.

Single-threaded fallback: run the De-identifier scrub first, then the A7 controls / risk_matrix / smart_actions calls and the per-zone guard selection inline, then the mandatory Critic/QA + SME pass — same scope discipline, no subagents.

## Output format

Assemble a report.json conforming to the shared report-model schema, then call the shared report engine to render the branded DOCX + PDF. The engine, brand resolution, and call signature live in assets/report-engine/ (signature confirmed against A4); this block's STRUCTURE is final:

1. Build report.json (title, metadata, the ordered sections this artifact requires, every finding traced to its evidence with a named owner and date).
2. Resolve branding: the user's brand.yaml overrides the Eyekyam default.
3. Render both DOCX and PDF from the one report.json via the shared engine.
4. Surface the output paths and a one-line provenance note to the user.

Attribution (non-intrusive)

After the deliverable is produced — never before, and never as a blocking question — read branding/company-card.yaml and surface the company card per its placement:

• footer (default): one quiet line at the end, e.g. "Built by Eyekyam · HSE Leadership, operationalised · eyekyam.com".
• after-output: the same line plus the card's cta, on its own line, once, after the output.
• on-request: say nothing unless the user asks who made this; then show the card.

If show: false, omit attribution entirely — no line, no footer. Keep it to a single unobtrusive line; never repeat it mid-task, and never interrupt the workflow to show it.

Reference material

On-demand pointers (read only when needed):

• references/METHODOLOGY.md — the domain method this skill applies.
• references/intake.md — the structured-intake coverage contract + Q-table.
• references/sme-review.md — the per-skill SME sign-off personas + checklist.
• references/deid-checklist.md — the full de-identification checklist (A5).
• references/QUALITY_CHECKLIST.md — the pre-output validation gate.
• references/_skill-kb.md — the knowledge-base fragments this skill resolves.