Accidents in process industries are increasing rapidly whereby it affects the employees and the productivity as well. A questionnaire is designed to evaluate the risk of machinery safety and accidents of employees in a 2700MW coal fired power plant. Thirty-one statements involving machinery reliability, equipment aging and operational control method elements are included with an open-ended statement for suggestions from the respondents chosen in the workplace. Reliability analysis is later performed and a Cronbach Alpha value of 0.9103 was recorded from the questionnaire which marks the effectiveness of the questionnaire. Data analysis shows that the accident level is higher in the area of machine reliability and employees have a lower awareness level on machinery reliability compared to equipment aging and operational control method. A Man to Machine (MTM) model is designed based on the results which involves the correlation of the relationship between employee and equipment using Multiple Regression Analysis (MRA). The model involves the accident root causes of a process equipment and the major hazards in the area of the equipment. The2 value of 0.559 is obtained from the MRA Statistic Data which determines that most statements from machine reliability contribute to the increase of accident rate of the power plant. The MTM model is synced to fit to the reduction of accidents under machine reliability and to increase the awareness among employees. © ESREL 2021. Published by Research Publishing, Singapore.