A Fresh Look At Machine Safeguarding

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A Fresh Look At Machine Safeguarding

• Presented By
• Jack Podojil
• CHCM, CHMM, REP, REA, ASA, CUSA

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Occupational Safety Health Act

• A new national policy was established on December
  29, 1970, when President Richard Nixon signed
  into law the OSHAct
• The OSHA Act took effect April 28, 1971 and was
  called the Williams / Stieger Act

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OSHA History

• The Congress of the United States declared that
  the purpose of this piece of legislation was to
  Assure so far as possible every working man and
  woman in the nation safe and healthful working
  conditions and to preserve our human resources.

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OSHA History

• The employer has the General Duty to furnish
  each employee with employment and a place of
  employment free from recognized hazards causing
  or likely to cause death or serious physical
  harm.

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An Employers Responsibility

• Provide a safe place of employment. (A plan)
• Provide a written safety and health plan to the
  employees.
• Communicate the plan to employees (Training)
• Enforce the plan.

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General Duty Clause

• For employers, the General Duty clause is used by
  OSHA when there are NO specific standards
  applicable to a hazard.

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ANSI Standards

• American National Standards Institute (ANSI) are
  standards developed by experts in the industry.
  These standards explain the hazards involved in
  operating machinery.
• Considered Best Practices

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ANSI Standards

• ANSI standards explain the hazards involved in
  operating machinery.
• ANSI standards are enforceable by law under the
  General Duty Clause.

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ANSI Standards For The Safety Professional

• ANSI TR-3 Risk Assessment.
• ANSI B-11.19 Safeguarding machinery as referenced
  by other ANSI B-11 standards.

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Machinery ANSI Standards Most Common.

• B11.2 Hydraulic presses
• B11.3 Press brakes
• B11.4 Shears
• B11.5 Iron workers
• B11.6 Lathes
• B11.8 Milling Drilling machines

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Machinery ANSI Standards.

• B11.9 Grinding machines
• B11.10 Metal sawing machines
• B11.21 Robotic safeguarding
• ANSI 01.1 Woodworking

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OSHA Standards

• OSHA standards are vague on many types of
  machines and often conflict with each other (for
  example
• 1910.213 of the woodworking standard states the
  top portion of a disc sander does not have to be
  guarded.

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OSHA Standards

• 29 CFR 1910.212 (a)(1) of the General Machine
  Guarding standard states One or more methods of
  machine guarding shall be provided to protect the
  operator and other employees in the machine area
  from hazards created by the point of operation,
  rotating part etc.

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The Problem

• It is presumed that machine designers strive to
  produce safe machinery.
• Today, manufactures still produce unsafe
  machinery. Example guards missing, controls
  inadequate, manuals that do not address the
  hazards.

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The Problem

• This equipment usually sells for 500.00 or less.
  Example Drill presses, saws, sanders, grinders,
  etc.
• Manufactures are not under OSHA jurisdiction
  unless their employees are exposed to the hazard.

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The Problem

• Would you like to buy machinery that is unsafe
  and expose your fellow employees to the hazards?
• Would you let your family, students or children
  run the equipment if you knew it was unsafe?

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Faulty Machine Design

• An effective machine guarding program must begin
  with a thorough analysis of the potential hazards
  found on all machinery located at a facility.
• The following are examples of faulty machine
  design.

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Faulty Machine Design

• Guarding missing.
• Inadequate strength of the guarding device.
• Improper color-coding of hazards.
• Emergency stops missing or not properly located.

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Faulty Machine Design
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Faulty Machine Design

• Electrical Controls and housings not properly
  rated for the environments they are in. NEMA 12
  for dust or moisture.
• Openings too large in guards. Example back side
  of drill presses and bandsaws.

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Machine Analysis

• Basically, your goal in conducting a hazard
  analysis will be to identify existing or
  potential hazard created by the machine
  operation.
• Both mechanical and non-mechanical items need to
  be inspected.

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Inspect Mechanical and Electrical Items
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Determine The Steps In Operating The Machine

• What hazard(s) is the operator exposed to while
  setting up or starting the machine.
• What hazard(s) is the employee exposed to while
  performing a particular job like operating or
  conducting maintenance.

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Identify Existing or Potential Hazards for Each
Operation

• Operator wearing long clothes or jewelry?
• Does the operator have set-up or loading
  unloading problems?
• How is the worker positioned while operating the
  machine?

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Evaluate The Cause of The Hazard

• Evaluate the cause of the hazard.
• Improper bid specifications.
• Improper monitoring installation of equipment.
• Improper training.
• Improper maintenance.

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Consumer Product Safety Commission (CPSC)

• Protects the public of hazards once they are
  known by recalling unsafe products.
• The CPSC requires that manufacturers notify the
  agency within 24 hours of obtaining information
  that their product does not meet a safety
  regulation.

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Consumer Product Safety Commission (CPSC)

• Do all manufacturers follow the rules?
• No Manufacturers like Jet, Grisley, Delta, and
  others produce unsafe machinery and may never
  contact CPSC even after they learn of a
  deficiency.

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What Can You Do?

• Get involved.
• Check CPSC web site and help report unsafe
  machinery located in your state.
• Develop a machine guarding committee in your area.

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State of Minnesota

• State of Minnesota forms the first machine
  guarding committee for schools.
• Intent of the committee is to protect children
  operating industrial type machinery.

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State of Minnesota Committee Members

• Department of Children families Learning (DCFL)
• Minnesota OSHA
• Minnesota Safety Council
• Minnesota Tech Prep
• Minnesota Teachers
• ReiTech Corporation

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State Of Minnesota

• Required each school district to appoint one
  person to attend an 8 hour training course in
  machine safeguarding.
• Required each school district to inspect and
  report each piece of machinery in their schools.

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State Of Minnesota

• Required each school district to develop an
  action plan to correct each piece of equipment.
• Develop a preventive maintenance plan.
• Required annual refresher training.

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Lockout, Tagout Tryout

• Too many times we speak of Lock-out Tagout
  (LOTO) and miss the most important feature the
  tryout phase.
• OSHA 1910.147 standard still ranks high on OSHAs
  hit list.

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Lockout, Tagout Tryout An Accident Revisited.

• Two workers seriously injured when they failed to
  tryout an electrical system that was miss marked.
• As the workers were preparing to remove a breaker
  they locked out the electrical system at the
  main.

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Lockout, Tagout Tryout An Accident Revisited

• The circuit was changed earlier and the panel was
  never remarked by the contractor.
• Employees were trained in (LOTO) but never took
  the final step to ensure that the energy was
  dissipated.

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Lockout, Tagout Tryout Accident Revisited.

• Employees used a metal ratchet to take the
  breaker out and the ratchet arched across 220 /
  480 volts causing an explosion.
• Employees suffered sever electrical burns.

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Lockout, Tagout Tryout

• Review your programs with your employees when you
  return to your sites.
• Ensure by conducting the annual audit that
  everyone is educated in the proper procedures.

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Questions Answers

• Do you have any?

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• The End Thank You