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What belongs in the assessment?
Assess the robot as part of the work system in which it will operate. That includes the robot, installation, software and control settings, tools and payloads, workpieces, connected equipment, work area, people, and tasks. Consider the intended use as well as foreseeable errors, malfunctions, and emergency conditions.
Start a written scope record with the facts that define the deployment:
- The exact work task, worksite, and expected operating conditions.
- The robot configuration, end-effector, payload, mobility, autonomy features, control modes, and operating speeds.
- Where the robot works, including its reachable area, blind spots, charging or storage locations, and any remote operator station.
- Connected machines, workpieces, and other equipment that can affect or be affected by the robot.
- Who may enter or work near the area: operators, maintenance staff, contractors, visitors, and other workers.
Set and document the system boundary. For example, a robot’s task cannot be assessed separately from a conveyor it feeds, the workpiece it handles, or the station where a worker clears jams.
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Which standards may apply to a humanoid robot?
Standards scope depends on intended use and the actual workplace application, not appearance. ISO 10218 is an industrial robotics series. ISO 10218-1:2025 addresses the robot as a machine; ISO 10218-2:2025 addresses integration into applications and robot cells. Both editions were published in February 2025.
| Standard | What it addresses | Scope qualification |
|---|---|---|
| ISO 10218-1:2025 | Industrial robot-level requirements | Its scope and exclusions must be checked against the intended use. |
| ISO 10218-2:2025 | Safety of integration into applications and robot cells | Assess the complete integrated application, not only the robot. |
| ISO/TS 15066:2016 | Supplementary guidance for collaborative industrial robot systems | ISO lists it as reviewed and confirmed in 2022 and current. Its industrial-system scope does not establish that it applies to every humanoid. |
ISO 10218 Parts 1 and 2 have exclusions that include some service, consumer, medical, and people-lifting applications, as well as limits related to public access and certain environments. Check the published scope and exclusions against the robot’s intended function, workplace access, task, and integration. A humanoid used in an industrial application may raise different standards questions from one used in a public-facing, medical, or lifting role.
In the United States, OSHA states that there are currently no specific OSHA standards for the robotics industry. OSHA’s robotics standards page describes consensus standards as guidance, not OSHA regulations. That does not remove employers’ duties under generally applicable workplace requirements or other applicable rules. Determine the requirements for the facility’s jurisdiction with competent safety and legal personnel; OSHA guidance is not a complete compliance answer for other countries.
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How to assess risks before commissioning
1. Map every task across the lifecycle
Do not limit the assessment to a normal demonstration cycle. List the work people will actually perform from delivery through ongoing operation and eventual changes to the system. Include transport and installation, commissioning, setup, teaching or programming, adjustment, routine operation, handoffs, jam clearing, cleaning, charging, inspection, maintenance, software or configuration changes, and recovery after a stop or fault. Account for both scheduled and unscheduled maintenance.
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For each activity, record who does it, what control mode is used, where the person must stand or reach, and whether the robot can move or restart. OSHA notes that robot incidents often occur during non-routine work such as programming, maintenance, testing, setup, or adjustment, when a worker may be inside the working envelope.
2. Identify hazards and exposure scenarios
Consider what could injure someone, how a person could be exposed, and what conditions could lead to that exposure. Prompts include:
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- Impact, crushing, pinching, or trapping between the robot and a fixed or moving object.
- Unexpected movement, loss of balance, or a falling robot.
- Contact with an end-effector, tool, payload, sharp or hot workpiece, or task-specific process hazard.
- Electrical or stored energy and noise.
- A person entering a reachable zone, being hidden in a blind spot, or approaching during a handoff or recovery.
- Foreseeable misuse or human error; sensor, communication, or control faults; power loss; and behavior after a stop, fault, or restart.
These are prompts, not a finding that every humanoid presents every hazard. Determine the actual exposure scenarios from the robot, task, surroundings, and people’s duties. Consider workers and contractors as well as the robot’s primary operator.
3. Determine requirements for this specific use
Compare the intended application with the scope of relevant standards and local workplace rules. For an industrial robot application, review ISO 10218-1:2025 for robot-level requirements and ISO 10218-2:2025 for integration and application or cell safety. ISO/TS 15066:2016 supplements ISO 10218 for collaborative industrial robot systems; it is not a blanket classification for humanoids.
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OSHA’s Technical Manual discusses risk assessment provisions in ANSI/RIA R15.06-2012 and related 2016 technical reports. Those references should not be mistaken for the newest ISO editions: ISO lists 2025 editions of ISO 10218 Parts 1 and 2. Confirm which standards, national adoptions, and legal requirements apply to the deployment and jurisdiction.
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4. Select controls and check the complete system
Use the identified exposure scenarios to decide which risk-reduction measures are appropriate, then verify them in the integrated application. Depending on the assessment, controls may involve the work area, access, robot or tool configuration, operating procedures, or fault response. No single safeguard is right for every system; competent personnel should select and validate controls for the actual hazards and intended use.
Review the robot together with its end-effector, payload, connected equipment, and completed application. Check that controls behave as intended during normal cycles and relevant non-routine conditions, including access, faults, stops, and recovery. A specification sheet or a vendor’s collaborative description cannot establish that the installed system controls the risks identified at the worksite.
5. Involve workers and prepare for operation
Have affected workers participate in hazard review and explain the safeguards, safe access, restricted areas, operating procedures, stop and recovery behavior, and how to escalate an unsafe condition. Match training to each person’s actual functions, including setup, operation, cleaning, and maintenance where applicable.
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Define how changes will be reviewed. A different task, workspace, tool, payload, software version, control setting, or maintenance method may change the risk assessment and require control checks before work resumes.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.What should be ready at the commissioning gate?
Before authorizing work, confirm that the assessment has led to verified protections and that the people who will use or maintain the system are prepared. OSHA’s Technical Manual says a robot application’s risk assessment should be performed and documented before commissioning, and also cautions that the presence of an assessment alone is not sufficient to ensure worker protection.
- A documented assessment covering the intended use, system boundary, tasks, people, hazards, and foreseeable non-routine conditions.
- Applicable technical documentation and a record of which standards and workplace requirements were considered.
- Verification results showing that selected controls were checked on the complete application.
- Operating, maintenance, access, stop, and recovery procedures appropriate to the deployment.
- Training records for affected workers and a method for reviewing changes and investigating incidents.
If critical details—such as the jurisdiction, task, tooling, payload, access arrangements, or integration—are not known, the deployment-specific conclusion remains open. Resolve those details and assess the actual system before commissioning rather than treating a generic humanoid assessment as approval.
How to compare candidate deployments or configurations
When choosing between robots, configurations, or work arrangements, compare them against the same intended task and conditions. The useful question is not which robot looks safer, but which complete application has risks that can be adequately controlled and verified.
- Task and environment fit: Can the configuration perform the intended work under the actual environmental conditions?
- People and access: Where can workers be relative to the robot, and how are access and possible contact addressed?
- Tools, payload, and integration: How do mobility, tooling, payload, workpieces, and connected machines affect hazards?
- Safeguards and faults: What controls are proposed, and what happens under relevant sensor, control, communication, power, stop, or recovery conditions?
- Lifecycle demands: What setup, maintenance, training, and non-routine work will be required?
- Validation evidence: What evidence demonstrates that controls work for the intended use, rather than only for a generic or different configuration?
What injury-rate evidence is available?
The official sources cited here do not provide a humanoid-specific workplace injury-rate statistic. OSHA describes individual serious and fatal robot incidents, but individual cases are not a rate and cannot establish how frequently a particular humanoid deployment will cause injury. Use the application-specific assessment and verified controls rather than an unsupported prevalence estimate.
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