What is non-routine operation and how does it affect risk assessment?

• A. Regular tasks requiring no extra controls
• B. Only software updates
• C. Operations not part of normal programmed tasks (e.g., setup, maintenance) requiring additional risk assessment and temporary controls.
• D. The same as routine operations

Answer: (C)

Non-routine operation means activities that fall outside the normal programmed tasks of a machine or system, such as setup, commissioning, adjustments, maintenance, or changeovers. Because these tasks are not part of the usual workflow, they bring in unfamiliar or evolving hazards that the standard controls may not cover. That’s why the risk assessment for these tasks must be done anew, identifying any new hazards, assessing how the equipment state and human factors change the risk, and deciding on temporary controls to manage those specific risks.

This approach is essential because routine tasks have established procedures and historical controls, while non-routine work introduces variability and uncertainty. It’s not just about a different activity type; it’s about the need to pause, re-evaluate hazards, and implement appropriate temporary measures, training, and oversight to keep people safe during that task.