A PUWER inspection is a structured, in‑depth check of work equipment to confirm it is suitable, safe and being used correctly in line with the Provision and Use of Work Equipment Regulations 1998. During a PUWER inspection, an inspector looks not only at the physical condition of the machinery or equipment, but also at how it is installed, operated, maintained and documented, so that any deterioration or unsafe practice can be detected and remedied in good time.
A PUWER inspection usually begins with preparation and planning, even before anyone looks at a single piece of equipment. The inspector will want to understand what work equipment is on site, where it is used, who uses it and what tasks it is used for, often by reviewing existing asset registers, maintenance records and previous inspection reports. This early stage of the PUWER inspection helps to prioritise higher‑risk equipment and plan a logical route around the workplace so that nothing is missed. It is also common at this point for the inspector to clarify who is responsible for health and safety on site and who will be the main point of contact during the PUWER inspection.
Before starting the physical walkthrough, the inspector will often hold a short opening meeting as part of the PUWER inspection to explain the purpose and scope of the visit. They will outline which items of work equipment are in scope of PUWER, such as fixed machinery, portable tools, access equipment and similar assets used at work. The inspector will also check that key personnel are available, that relevant documents can be accessed quickly, and that any permits or safe systems of work needed for the PUWER inspection itself are in place. This sets expectations for the rest of the PUWER inspection and helps avoid delays once the site tour begins.
Documentation review is an important part of a PUWER inspection because it shows whether equipment is being managed correctly over its whole life. During this stage of the PUWER inspection, the inspector looks at instructions from the manufacturer, risk assessments, maintenance logs, previous inspection reports and training records for operators. They will check whether inspections are being carried out at suitable intervals in line with Regulation 6, whether defects have been picked up in good time and whether any remedial actions have actually been completed and recorded. A well‑kept documentary trail makes it far easier to demonstrate compliance during a PUWER inspection and can also highlight patterns of recurring issues.
Once the paperwork has been reviewed, the inspector moves on to the physical examination of work equipment as the core of the PUWER inspection. Here the focus is on whether equipment is suitable for the task, correctly installed and in a condition that does not expose people to risk. This part of the PUWER inspection involves checking the state of structural components, looking for signs of damage, corrosion or excessive wear, and confirming that protective devices are in place and effective. The inspector will often compare what they see on the shop floor with what is written in the paperwork to determine whether the arrangements described in procedures are actually being followed during the PUWER inspection.
Guarding and safety devices are examined in detail during a PUWER inspection because they form a primary barrier between people and dangerous parts. The inspector will check that fixed and interlocked guards are correctly fitted, robust, and cannot be easily defeated, and that distances and openings are appropriate so that hands or clothing cannot reach moving parts. As part of the PUWER inspection, they will also look at other protective measures such as light curtains, pressure‑sensitive mats, emergency stop buttons and local exhaust ventilation where relevant, confirming they are present, accessible and in good working order. Any makeshift or damaged guarding found during the PUWER inspection is likely to be treated as a significant defect that needs prompt action.
Controls and emergency arrangements are another key focus during a PUWER inspection. The inspector will check that normal start and stop controls are clearly identified, within easy reach of the operator and designed so that the equipment does not start unexpectedly, for example after a power cut. As part of the PUWER inspection, they will operate emergency stop devices to see whether they work correctly and stop the equipment quickly enough to prevent injury, while also ensuring they are not used as routine controls. The inspector may also review isolation and lock‑off arrangements during the PUWER inspection to be sure that maintenance tasks can be carried out safely.
During a PUWER inspection, the inspector will observe how equipment is actually used in practice and compare this with the intended safe methods. They may speak with operators to confirm their understanding of the controls, the guarding and any particular hazards, and to check whether they have received appropriate information, instruction and training. The PUWER inspection will look at whether unauthorised use is being prevented, for example through key control or supervision, and whether safe systems of work are being followed during set‑up, cleaning, adjustment and maintenance. This behavioural element of the PUWER inspection helps identify gaps that might not be obvious from the equipment itself.
Risk assessment sits in the background of every PUWER inspection, influencing how issues are judged and prioritised. The inspector will consider the likelihood and severity of harm associated with each piece of equipment and assess whether existing safeguards reduce risk to a level that is as low as reasonably practicable. During the PUWER inspection, they will also check whether formal risk assessments exist for the equipment, whether they are up to date and whether they cover all relevant tasks, including non‑routine activities such as clearing blockages. Where the PUWER inspection reveals missing or inadequate risk assessments, this is usually recorded as a finding requiring management attention.
Another aspect that is examined closely during a PUWER inspection is the maintenance and inspection regime for work equipment. The inspector will look for evidence that equipment exposed to conditions causing deterioration is inspected at suitable intervals, that preventive maintenance is carried out and that faults are reported and corrected promptly. In a PUWER inspection, particular attention is paid to items whose failure could have serious consequences, such as brakes, limit switches, emergency stops and structural components, because deterioration here can quickly lead to dangerous situations. The inspector may use a risk‑based approach within the PUWER inspection to judge whether existing intervals for checks and servicing are appropriate or need to be adjusted.
When defects are found during a PUWER inspection, the immediate question is whether the equipment can continue to be used safely. If a serious defect presents an imminent risk of injury, the inspector will usually recommend that the equipment is taken out of service straight away, clearly labelled as unsafe and not returned to use until repaired and, where necessary, re‑inspected. Less serious issues identified during a PUWER inspection might not require immediate shutdown, but they will still need to be addressed within a reasonable timescale and monitored to make sure they do not worsen. In all cases, the PUWER inspection aims to ensure that any deterioration is detected and remedied before it leads to unacceptable risk.
Record‑keeping is a legal and practical requirement that flows from every PUWER inspection. At the end of their visit, the inspector will compile a record setting out which items of equipment were inspected, when the PUWER inspection took place, who carried it out and what was found. This report from the PUWER inspection will list defects or non‑compliances, categorise their severity and indicate what remedial actions are required, as well as any timescales for completion. These PUWER inspection records must be kept and made available for review, providing evidence of compliance and a reference point for future inspections and audits.
At the close‑out stage of a PUWER inspection, the inspector will usually hold a debrief with management to discuss key findings and recommended actions. They will highlight any issues that require urgent attention, such as missing guards or non‑functional emergency stops, as well as more strategic improvements like updating procedures or enhancing training programmes identified during the PUWER inspection. This conversation allows duty holders to clarify anything in the PUWER inspection report, ask questions about priorities and confirm who will be responsible for follow‑up actions. It also reinforces the message that a PUWER inspection is not just a tick‑box exercise but part of an ongoing process of managing work equipment safety.
After the PUWER inspection, the real value comes from acting on the findings rather than simply filing the report away. Duty holders must plan and complete remedial work, update risk assessments, revise safe systems of work where needed and ensure that any changes are communicated to staff, often using the PUWER inspection as a catalyst for broader improvements. In some cases, a follow‑up PUWER inspection or targeted re‑inspection may be arranged to confirm that critical issues have been resolved and that equipment can be returned to full service safely. Treating each PUWER inspection as part of a continuous improvement cycle helps maintain safe, reliable equipment and demonstrates a proactive approach to health and safety management.