Risk assessment is a sequential process which requires understanding the hazards and analyzing risks associated, to determine required safety measures, like safeguarding to mitigate the risks to an acceptable level. In this article a thorough task-based risk assessment process is conducted in the early stage of layout design and building of a collaborative cell for sealing application performed in aircraft industries using a medium sized industrial robot system integrated with safety control functions. This article will also discuss how simulation could contribute in eliminating the threats as required by the safety standards before investing in equipment for collaborative cell layout.