CSA Z432 Third Edition Open for Public Review!

CSA Z432, Safeguarding of Machinery, is the basic standard for Canada when it comes to most types of machinery. Only Power Presses and Press Brakes, and Industrial Robots are covered separately in their own standards. CSA Z432 provides guidance on important topics, like:

  • Risk Assessment
  • Risk reduction through the Hierarchy of Controls
  • Guard design requirements
  • Safeguarding device application requirements, and
  • Instructions and information for use

This standard should be used by everyone in Canada responsible for the safe design of machinery used in Canadian workplaces, and for the safety of workers who use machinery in their daily tasks.

CSA has just opened public review on CSA Z432, Safeguarding of Machinery, third edition. If you are a user, a builder of machinery, or an evaluator of machinery, this is your opportunity to see the draft of this important standard, and to make comments to help the Technical Committee improve the standard on your behalf.

To access the public review copy, you must register on CSA’s Public Review system. Registration is free and allows you to get read-only access to the drafts of all new standards that CSA is preparing to publish. The time you take to read and comment on new standards is very valuable to the Technical Committees, as it helps us to correct areas where misunderstandings or confusion may exist, and to add material where it is needed.

See the Draft

Review closes 2-Jan-2016, so don’t delay!

If you need more information, please contact Jill Collins at CSA Group.


Translation Bafflement

iStock_000009386795Small - Photo of Instruction manualI’ve been noticing a trend with some of my clients that I am having a really hard time understanding – maybe a reader can help me get this…

A basic requirement in the EU is that manuals and other information a manufacturer provides to their customer be provided in the official language of the country where the product is being sold. One possible way around this is to provide a graphical set of instructions. Probably the best example of this is IKEA, where everything is done graphically.

To me, this is only logical, after all, if I buy a product I’d like to be able to read the instructions in English, and I can’t imagine that other people wouldn’t want to read the instructions in their native language too.

But here’s the thing—I regularly have clients who don’t want to translate their instruction manuals. They look for every possible excuse, from ‘those guys didn’t do it’, referring to a competitor, to ‘the customer speaks and reads English, so we don’t need to translate’. The first excuse is laughable in my opinion, and the last one is at least somewhat plausible, but the law requires translation. Simple. Sell the product in Germany, provide instructions in German. Sell it in Italy, provide instructions in Italian.

IKEA Desk Chair Instructions
Graphical Instructions, IKEA Style

This even holds true here in Canada where I live. In most of Canada, English is predominant, but every package is marked in English and French, and instructions are provided in English and French. Why? Because we have two official languages, English and French.

So what’s the big deal? I understand that there is a cost attached to translation, but it’s a cost of doing business in another market and should have been easily foreseeable in developing the product budget.

If you can explain this to me, I’d love to hear from you!

The Third Level of the Hierarchy: Information for Use

This entry is part 3 of 3 in the series Hierarchy of Controls

I’ve written about the Hierarchy of Controls in past posts, but I’ve focused on the ‘engineering’ side of the control equation: Physical changes to machine design to eliminate hazards, and mechanical or electrical control systems that can reduce risk.

The first two levels of the Hierarchy, Elimination/Substitution and Engineering Controls, are typically more challenging to apply in most people’s minds, because expert knowledge is required. These levels are also more effective in controlling risk than the subsequent levels.

The Third Level

iStock_000009386795Small - Photo of Instruction manualThe third level of the Hierarchy is ‘Information for Use’, sometimes abbreviated as ‘IFU.’ This level is deceptively simple, and is frequently the level people want to jump to when the other controls seem too difficult to implement. Done well, information for use can make a significant contribution to risk control. Unfortunately, it’s done poorly or not at all more often than it’s done well.

Information for use includes:

  • Instructions and Manuals;
  • Operator Device tags and Legend Plates;
  • HMI screens;
  • Hazard Warning signs and labels;
  • Training Materials (text, video, audio) and Training (face-to-face, webinars, self-directed);
  • Sales and marketing materials.

Information for use is needed in all the stages of the product life cycle: Transportation, Installation, Commissioning, Use, Maintenance, Service, Decommissioning and Disposal [1]. At each stage in the life cycle, the content of the information and the presentation may be different. In every stage it can make a significant contribution to risk reduction by communicating the safe approach to the tasks in that stage, and the risks related to those tasks. The information should include the intended use and the foreseeable misuses of the product. This is a legal requirement in the EU [2], and is a best-practice in North America.

In this article I’m going to focus on instruction manuals. If you’re interested in Hazard Warnings, including signs, labels, and integration into manuals and instructions, watch for a future post on this topic.

Legal requirements and standards

In the European Union, the legal obligation to provide information with a product is enshrined in law [2].
No North American jurisdictions make an explicit requirement for instructions or information for use in law, but many product specific standards include requirements for the content of manuals.

CSA Z432 [3] outlines requirements for content in Clause 17, and in EN 60204-1 [7]. IEC 62079 [4], provides guidance on the design and presentation of instructions. ANSI Z535.6 [5], provides specific instructions on inclusion of hazard warnings in manuals and instructions.

Training requirements are also discussed in CSA Z432 [3], Clause 18.

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In the USA, providing information for use with a product is considered to be sound ‘due diligence’, however, providing information on residual risk is often seen by liability lawyers as dangerous, since manufacturers are providing information, in writing, that their product is not ‘perfectly safe.’ If you’ve read anything I’ve written on risk assessment, you’ll know that there is no such state as ‘perfectly safe.’ If a hazard exists, a potential for harm exists, a probability can be assessed and thus risk exists, however remote that risk may be. I think that this argument by some liability lawyers is fatuous at best.

Kenneth Ross, one of the leading product liability lawyers in the USA, discusses the requirements for warnings and instructions in an article published in 2007 [6]. In the article, he explains the US requirements:

“Product sellers must provide “reasonable warnings and instructions” about their products’ risks. The law differentiates warnings and instructions as follows:

“Warnings alert users and consumers to the existence and nature of product risks so that they can prevent harm either by appropriate conduct during use or consumption or by choosing not to use or consume.”

Instructions “inform persons how to use and consume products safely.”

A court has held that warnings, standing alone, may have no practical relevance without instructions and that instructions without warnings may not be adequate.

Therefore, when the law talks about the “duty to warn,” it includes warnings on products in the form of warning labels; safety information in instructions; instructions that affirmatively describe how to use a product safely; and safety information in other means of communication such as videos, advertising, catalogs and websites.

The law says that a manufacturer has a duty to warn where: (1) the product is dangerous; (2) the danger is or should be known by the manufacturer; (3) the danger is present when the product is used in the usual and expected manner; and (4) the danger is not obvious or well known to the user.”

Read Mr. Ross’ latest article on warnings.

This practical and sensible approach is very similar to that in the EU. Note the requirement that “instructions that affirmatively describe how to use a product safely.” The  old list of “don’ts” doesn’t cut it – you must tell your user how to use the product in an affirmative way.

Second Best

So why is it that so many manufacturers settle for manuals that are barely ‘second best’? In many companies, the documentation function is:

  • Not seen to add value to the product;
  • not understood to have legal import in limiting product liability;
  • given little effort.

The perception seems to be that manuals are produced primarily to fill filing cabinets and that customers don’t use the information provided. This leads to manuals that are written after-the-fact by engineers, or worse, the role of ‘technical writer’ is seen to be an entry level position often filled by interns or co-op students.

End-user training is frequently given even less thought than the manuals. When designed together, the manual will support the training program, and the trainers can use the manual as one of the primary training tools. This provides continuity, and ensures that the training process is properly documented.

iStock_000012657812Small - Techncial ManualMy experience is that few engineers are excellent writers. There are some, no doubt. Writing manuals takes a sound understanding of educational theory, including an understanding of the audience to whom the material is directed. The level of technical sophistication required for a simple household product is completely different from that required for the technical support manual for an industrial welding laser.
The engineers designing and integrating an industrial system are often too close to the design of the product to be able to write effectively to the target audience. Assumptions about the level of education that the user will have are often incorrect, and key steps may be skipped because they are assumed to be ‘common knowledge.’

Quality documentation is also a customer service issue. Products that are well documented require less customer service support, and when customers do need support, they are generally more satisfied with the result.

New Delivery Methods

The delivery methods for technical documents have changed considerably in recent years. Large, ring-bound paper manuals are being displaced by on-line, interactive documentation that can be accessed at the user interface. The use of PDF-format manuals has jumped, and this brings in the ability to link error messages generated by the control system to the sections of the manual that related to that aspect of the system. Video and animations can be added that provide at-a-glance understanding of the operation of the machinery. WiFi networks in industrial facilities, along with the acceptance of mobile pad-computing devices like the Apple iPad, mean users can have the instructions where they need them, and technicians and service personnel can take the manual with them to the area where a problem exists, and can use the documents even in very low-light conditions.

Finding technical writing resources can be a challenge, particularly if you are looking to move away from paper to electronic documentation. The standards mentioned in this article are a good place to start.
Documentation can range from writing through technical illustrations, animation and video production. Finding individuals who can provide you with professional services in these areas in a timely way and at a reasonable price is not an easy task. If you need assistance ranging from a few questions that need answers to hiring a technical writer, Compliance InSight Consulting can help. Contact me for more information!

Are your product manuals as good as they could be? What kinds of challenges have you had with getting them written, or used? Add your comments below!


5% Discount on ISO and IEC Standards with code: CC2011

[1]    “Safety of machinery – General principles for design – Risk assessment and risk reduction”, ISO Standard 12100, 2010

[2]    “DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 17 May 2006 on machinery, and amending Directive 95/16/EC”, Annex 1, Clause 1.7, European Commission, 2006.

[3]    “Safeguarding of Machinery”, CSA Standard Z432, Canadian Standards Association, 2004.

[4]    “Preparation of instructions – Structuring, content and presentation”, IEC Standard 62079, International Electrotechnical Commission, 2001.

[5]    “American National Standard For Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials”, ANSI Standard Z535.6, American National Standards Institute, 2006.

[6]    K. Ross. “Danger! The Legal Duty to Warn and Instruct”, Risk Management Magazine, [web] 2007, Available: No longer available.

[7]      “Safety of machinery — Electrical equipment of machines — Part 1: General requirements”, CENELEC Standard EN 60204-1, CENELEC, 2009.