Machinery Safety in NZ: Risk Assessments, SOPs & Training

12 Nov Machinery Safety in NZ: Risk Assessments, SOPs & Training

What to Do When Introducing New Machinery to Your Business – A Health and Safety Guide for NZ Workplaces

Bringing in new machinery is an exciting milestone for any business. It often means higher productivity, better quality, and growth opportunities. But every new machine also comes with new risks – and under the Health and Safety at Work Act 2015, New Zealand businesses have a duty to manage them.

Here’s a practical, step-by-step guide to safely introducing new machinery into your workplace, staying compliant with NZ health and safety laws, and protecting your team.

1. Conduct a Machinery Risk Assessment

Before using any new equipment, carry out a risk assessment to identify and control potential hazards such as:

• Moving parts and entanglement risks;
• Electrical hazards and energy sources;
• Noise, vibration, or emissions; and
• Manual handling or ergonomic strain.

Use the hierarchy of controls to eliminate or minimise risks where possible – and document your findings.

Tip: Keeping written records of your risk assessments helps prove compliance with WorkSafe NZ.

2. Review Manufacturer Safety Information

Always read and understand the manufacturer’s operating manual before use. It outlines safety features, maintenance needs, and correct procedures.

Use this information to help create your Safe Operating Procedure (SOP) and ensure the machinery is used exactly as intended. If the manual doesn’t address your specific work environment, contact the supplier for clarification or training support.

3. Develop or Update Safe Operating Procedures (SOPs)

A Safe Operating Procedure is your frontline control for safe machinery use. Your SOP should include:

• Step-by-step safe operation instructions;
• PPE requirements;
• Pre-start checks and shutdown procedures; and
• Emergency responses and lockout steps.

Having clear SOPs ensures consistent, compliant, and safe use of machinery.

Need help writing one? Check out our 220+ Safe Operating Procedures available to purchase.

4. Provide Training and Verify Competency

Never let untrained staff use new machinery. Provide thorough training and supervision, covering:

• How the machine works;
• Safe operating steps;
• Emergency shutdowns; and
• Reporting faults or incidents.

Keep training and competency records – WorkSafe NZ will request these in the event of an incident or inspection.

5. Review Emergency Procedures

New machinery may change your emergency or first aid requirements. Update your emergency plans to include:

• Isolation procedures;
• Fire or electrical fault responses;
• First aid kit access; and
• Evacuation routes.

Make sure all staff know what to do and where to go in an emergency.

6. Establish a Maintenance and Inspection Schedule

Ongoing maintenance and inspections are critical for machinery safety.

• Follow the manufacturer’s maintenance schedule;
• Keep a maintenance log;
• Conduct regular pre-start checks; and
• Repair or replace faulty parts immediately.

A well-maintained machine is a safer and more reliable one.

7. Consult with Workers

Under the Health and Safety at Work Act 2015, you must consult your workers on health and safety matters, including when new equipment is introduced.

Encourage open communication – your team can often spot hazards and suggest safer ways to work.

8. Monitor, Review, and Improve

After installation, monitor how the machine is used. Check for unsafe shortcuts, unreported faults, or changes in risk.

Regularly review your SOPs, training, and incident data to ensure your system stays up to date and effective.

Make Machinery Safety a Priority

Introducing new machinery to your workplace is an opportunity to strengthen your safety culture. By assessing risks, developing proper procedures, and providing quality training, you’ll protect your people, stay compliant with NZ law, and get the most from your investment.

Please contact us if you need advice introducing new machinery into your business.

Frequently Asked Questions About Introducing New Machinery

What are the health and safety requirements for new machinery in New Zealand?

Under the Health and Safety at Work Act 2015, businesses must ensure any machinery used in the workplace is safe. This includes conducting a risk assessment, providing training, maintaining equipment, and having a written Safe Operating Procedure (SOP) in place.

Do I need a Safe Operating Procedure for every machine?

Yes. Every piece of machinery – whether new or existing – should have its own SOP outlining safe operation, PPE requirements, maintenance steps, and emergency procedures. SOPs are a key part of a compliant health and safety system in NZ.

Who is responsible for machinery safety in the workplace?

The Person Conducting a Business or Undertaking (PCBU) – usually the business owner or manager – holds primary responsibility for machinery safety. However, workers must also take reasonable care for their own safety and follow all SOPs and training.

What happens if machinery causes an injury at work?

If a machine-related injury occurs, you must:

• Provide first aid and ensure the scene is safe;
• Notify WorkSafe NZ immediately (for notifiable injuries);
• Record the incident and review your SOP and training records; and
• Take corrective action to prevent recurrence.

Where can I get Safe Operating Procedures for my business?

You can purchase customisable Safe Operating Procedures from us. Check them out here>>>

Other suggested articles:

• Continuously Improving the PDCA Cycle
• Getting Creative with Employee Training
• Working with Safe Operating Procedures
• Safe Operating Procedures

Please contact us if you would like to discuss.