The Machine Safeguarding Process

12/12/2013
Workplace Engineering Solutions
Kristin Petaski, P.Eng
Mike Gordon, P.Eng
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12/12/2013
What we will cover:
◦ Introduction to Safeguarding
◦ Safeguarding Process
Identify Hazards
Risk Assessment
Safeguarding Controls
◦ Case Studies
◦ Questions?
Safeguarding is the use of different measures
to effectively provide protection from contact
with hazardous conditions.
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Accidents associated with unguarded
machinery tend to be very serious.
Accidents can happen to new operators,
experienced operators and bystanders.
Injuries cost companies a lot of money (WCB,
lost production, hiring/training new workers)
Part 16 refers to Machines, Tools and Robots.
Section 16.5(2) states:
An employer must ensure that any safeguard
required under this Part is designed,
constructed, installed , used and maintained
in accordance with CSA Standard Z432
Z432-04,
Safeguarding of Machinery.
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CSA standard for the minimum recommended
safeguards on machinery in order to protect
workers.
We are required by MB legislation to meet this
standard.
Follow the safeguarding process, the
standard outlines the need for a risk
assessment.
When safeguards are selected, use the
standard to verify the correct application and
performance requirements.
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DO YOU HAVE A SAFEGUARDING PLAN AND
TIMELINE FOR YOUR FACILITY?
Take control of
this process.
The first step in planning your project is
understanding the scope of work.
List all equipment in your plant, and major
hazards associated with them.
Create a priority list to focus the safeguarding
effort.
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1.
Identify Hazards: Where can you get hurt?
2.
Risk Assessment: Which ones are most
dangerous?
3.
Safeguarding controls: What is currently in
place? What needs to be added?
Mechanical Hazards
◦ Rotating parts (shafts, feed rolls, pulley drives, etc)
◦ Reciprocating parts (punch press, cylinders)
◦ Parts that rupture (abrasive wheel)
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Electrical Hazards
◦
◦
◦
◦
Explosion, electric shock, or burn
Contact with live parts
Parts that become live on fault condition
Also, falls created by result of surprise of electrical
shock
Health Hazards
◦
◦
◦
◦
◦
Hazards that you can absorb, inhale, ingest.
Heat, noise, vibration
Toxic chemicals & fumes
Radiation
Repetitive motion injuries
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A tool used to measure the danger of each
hazard
Used to determine priorities
Used to select safeguards
Performed by a multi-functional team
(operator, supervisor, maintenance, safety
rep)
Frequency:
10
9
8
7
6
5
4
3
2
1
0.5
continuous
every 15 minutes
every 1/2 hour
4-8 times daily
2-4 times daily
Once daily
Weekly, occasionally
Bi-weekly
Monthly
A few times a year
Very rare
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Severity:
◦
◦
◦
◦
◦
◦
◦
◦
◦
◦
◦
◦
◦
◦
100
80
60
40
30
20
15
11
7
5
3
2
1
0.5
Catastrophic, many fatalities (10+)
Disaster, multiple fatalities (5-10)
Disaster, multiple fatalities (4-5)
Disaster, multiple fatalities (2-3)
Fatal
Grave, likely fatal
Very serious
High (amputation, blindness)
Serious injury
Long term disability
Important, time loss injury
First Aid by a professional
Noticeable, possible first aid
Insignificant, minor bruise
Likelihood:
10
9
8
7
6
5
4
3
2
1
0.5
0.2
0.1
Might well be expected
Probable
Likely
As likely as not
Quite possible
Reasonably foreseeable
possible
unusual, but possible
unlikely
remotely possible
conceivable
practically impossible
virtually impossible
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Likelihood
Risk
Punch Part
Severity
1
Activity
Frequency
Item #
#of people
These three factors are combined to
determine the risk from a task and its
corresponding hazard
There are a number of ways to do a risk
assessment, as long as they are equal or
more stringent than the method described
in CSA Z432-04
1
9
11
6
594
Finger can access
punch from sides
of machine
2
9
11
6
1188
Shards in
face/eyes
Tool/Part shatters
1
9
4
4
144
Crush
Part stripper not in
place
1
9
5
9
405
Crush/Amputation Accidental trigger
1
9
11
7
693
Hazard
Finger caught
between punch
Crush/Amputation
and part
2
3
4
Punch Extration
5
Cycle Machine
Cause of Hazard
10
1
9
11
6
594
Risk
Risk
Finger
caught
between
punch and
part
Current Controls
#of people
Frequency
Severity
Likelihood
Likelihood
Crush
Severity
Punch
Part
Cause of
Hazard
Frequency
Activity Hazard
#of people
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Hold-to run/Anti1 9 11 4 396
repeat foot pedal
Hierarchy of Controls
Effectiveness decreases as you move lower
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Ideal situation if possible.
◦ Eliminate a fall hazard by bringing work to
ground level.
Substituting involves removing the
hazard just like elimination, but
substitutes in a lesser hazard.
◦ Using an acrylic paint rather than a lead based
paint.
Next best solution.
Isolate workers from the hazard.
Capital costs tend to be higher than the
less effective controls within the
hierarchy.
Must be designed with the work
performed in mind.
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Best option if
possible
Fixed or interlocked
AUTO
◦
◦
◦
◦
Around
Under
Through
Over
Guards can be self-adjusting to allow for
product variation
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Anti-Repeat
Hold-to-Run
Anti-Tie-Down
Shrouded
Safe Distance
ONLY PROTECTS
THE OPERATOR!
Does not prevent
access, prevents
dangerous motion
Flexible solution
Light curtains,
lasers, safety mats
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◦ How do you know where to place safeguards?
◦ Stop Time Device measures the stopping time of
machine, including electrical components
◦ Formula is used to determine safe distance to place
controls
VIDEO
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Red in colour with a
yellow background
Unguarded
Palm or mushroom
head type
Type requiring
manual reset
Resetting the
button shall not
initiate a restart
Electrical Inspection
◦
◦
◦
◦
◦
Properly labelled disconnect
Can it be only locked in the off position?
Is Machine grounded correctly?
Are all controls labelled correctly?
Does machine have a nameplate?
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Control Reliable Safety Circuit
◦ Control reliable shall be dual channel with
monitoring.
◦ If the safety control system fails, the machine will
still stop!
Painted floor
Horns & sirens
Warning decals
Lights
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Low on the hierarchy but very important
Procedures, training, etc.
Best used to compliment other measures
Plant Policy
Machine Specific
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Emergency Plans
◦ Be Prepared
Training
◦ Regular & Documented
Inspections
◦ Formal & Informal
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Punch
Part
Finger
caught
Crush between 1 9 11 6 594
punch
and part
Hinged guard
across front,
interlocked
Risk
Likelihood
Severity
Proposed
Controls
#of people
Frequency
Cause of
Hazard
Risk
Activity Hazard
#of people
Frequency
Severity
Likelihood
Safety glasses
Hearing protection
Safety boots
Gloves
Respirators
1 9 11 0.2 19.8
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Purpose:
◦
◦
◦
◦
◦
Review of all hazards
Identify areas of concern
Provide solutions to meet CSA Z432-04
Proof of machine compliance with legislation
Include in your purchase agreement for new equipment
Procedure:
◦ Perform a risk assessment
◦ Review of current safeguards
◦ Determine areas that do not comply with safeguarding
standard
◦ Provide a list of guarding solutions to meet standard
Hazards:
◦ Point of Operation (Two-hand controls)
◦ Third Parties (tooling, pinch points)
◦ Control System
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Solutions:
◦
◦
◦
◦
Upgraded Two-Hand-Controls & Estop
Side Fencing
New Control Panel with Category 4 Safety Relay
Interlocked Ram Blocks
Hazards:
◦ Insufficient safeguarding for operator
◦ No control for second operator
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Solution:
◦ Use existing
2-hand
controls
◦ Add another
control stand
for second
operator
Hazards:
◦ Access to point of operation
◦ Used for both continuous and one cycle operations
◦ Two Hand Controls not at safe distance
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Solution:
◦ Install
programmable
light curtains
◦ Upgrade two
hand station
MAY 4 – 10
Make Safety a Habit
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12/12/2013
Bridging the gap between production & safety
through technical expertise.
PO Box 35010
963 Henderson Hwy
Winnipeg, MB R2K 2M0
www.workengsolutions.ca
[email protected]
204-805-0960
204-785-0616
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