MACHINE SAFETY: ALWAYS BE REVIEWING RISK Your complete solution to production safety and performance

Your complete solution to production safety and performance About us Mike Gordon, P.Eng Kristin Petaski, P.Eng Introduce ourselves, manufacturing engineers (not h&s people!), how we got started, our experience Your complete solution to production safety and performance www.workengsolutions.ca

Vision Statement: Mission Statement: We believe it is possible to have a world in which machine injuries are a thing of the past, hazards are engineered away and every worker goes home safely to their families every single day. Mission Statement: Our mission is to use a technical approach to provide safe and productive solutions to effectively safeguard equipment in order to eliminate machine-related injuries. We believe all machine incidents are preventable and we will work together with our clients to: Create a safe working environment for their employees, Ensure all of their machines are compliant with all standards and regulations, and Be the known experts on machine safety.

Outline What we will cover: Risk and Machine Safety Proactive versus Reactive Risk Assessments Review Strategies Machine Safety Programs Metrics and Best Practices

Risk and Machine Safety We are going to use machine safety to talk about risk, how to identify it and how to address it in a continuous improvement manner. Can you touch a hazard? Barrier guards, presence sensing devices, 2 hand controls How to you guard and still make product?

Machine Safety The use of different measures to effectively provide protection from contact with hazardous conditions. Can you touch a hazard? Barrier guards, presence sensing devices, 2 hand controls How to you guard and still make product?

Proactive versus Reactive 1. An Injury Occurs 2. An Improvement Order is Issued 3. We Decide to be PROACTIVE

Cost of Safety INJURY $150,000 PROACTIVE $10,000 IMPROVEMENT ORDER Production & Worker Loss $40,000 WSH Fine $40,000 WCB $5,000 Court Expenses $50,000 Improve Machine Safety $15,000 IMPROVEMENT ORDER $30,000 Production Loss $10,000 Expedite Project $5,000 Improve Machine Safety $15,000 PROACTIVE $10,000 Improve Machine Safety $10,000

Root Cause of Reactive Lack of understanding of standards/regulations. Lack of awareness of hazards Unbudgeted, unplanned projects. Reliance on awareness or administrative controls. Not following a safeguarding process. Lack of engagement. Poor solutions that don’t take the process in mind. Injuries, disfigurement, amputations, death Focus on cost, ROI for having a plan Safety is important, but a good safety solution should not forget the job to be done Room for safety with productivity Safe work is productive work

How to be PROACTIVE… Understand your current state: How many machines do you have? How many machines have little or no guarding at all? Are you relying on awareness guards and administrative controls? Do you have any documentation showing hazard identification and risk analysis for each machine?

How to be PROACTIVE… Create a plan: Inventory of equipment, Understand what standards/regulations you must comply to, Have a budget, Determine priorities based on risk evaluation, Generate a feasible timeline.

How to be PROACTIVE… Take it one step at a time: Assess each piece of equipment and create a guarding plan, Team effort, Don’t get overwhelmed, Ask for expert help, Continuous improvement – this won’t be done overnight.

Risk Assessments What are they? Why do we need them? How do we do them? When are they reviewed? Read section 16.5(2)

CSA Z432-16: Safeguarding of Machinery CSA standard for the minimum recommended safeguards on machinery in order to protect workers. Read section 16.5(2)

How are standards applied to Safeguarding? 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. Explain that the CSA standards don’t outline what controls to pick, but when selected, how they should be applied.

Safeguarding Process Identify Hazards: Where can you get hurt? Risk Assessment: Which ones are most dangerous? Safeguarding controls: What is currently in place? What needs to be added? Important to follow a process

Identifying Hazards Mechanical Hazards Rotating parts (shafts, feed rolls, pulley drives, etc) Reciprocating parts (punch press, cylinders) Parts that rupture (abrasive wheel) Instead of reading slide, maybe explain pictures

Identifying Hazards 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 Walk the operator path, look all around

Identifying Hazards Health Hazards Hazards that you can absorb, inhale, ingest. Heat, noise, vibration Toxic chemicals & fumes Radiation Repetitive motion injuries Not as obvious as mechanical, but very dangerous

Risk Assessment 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)

Risk Assessment Step 1: Identify Tasks Step 2: Determine Hazards of Each Task Step 3: Determine Risk Rating for Each Task

Info for a Risk Assessment 1. Previous Risk Assessments 2. Near Misses 3. OEM Info

What are the tasks and hazards? Pg 18 in guideline, lowest protection is at the bottom

Permanent Injury or death Risk Assessment Severity S0 Minor S1 Major S2 Permanent Injury or death Frequency F1 Infrequent F2 Frequent Probability P1 Unlikely P2 Likely Need to calibrate and make sure all team members on a risk assessment are on the same page

Risk Assessment – Radial Saw Item # Activity Hazard Cause of Hazard Frequency Severity Likelihood Risk 1 Cut Part Laceration/ Amputation Hand contacts rotating blade 2   Struck by  Part kicks back 3 Shards in face/eyes Part chips 4 Bystander in area Laceration / Amputation Bystander contacts rotating blade 5 Change Blade Accidental activation Scoring system creates hierarchy of Risk Explain

ELIMINATE OR SUBSTITUTE Hierarchy of Controls Effectiveness decreases as you move lower HIERARCHY OF CONTROLS ELIMINATE OR SUBSTITUTE ENGINEERED CONTROLS AWARENESS Pg 18 in guideline, lowest protection is at the bottom ADMINISTRATIVE CONTROLS PPE

Eliminate or Substitute 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. Auto-load a machine

Engineered Controls 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.

Awareness Painted floor Horns & sirens Warning decals Lights Great starting point, good exercise for starting to identify hazards Best used in combination with other safeguards

Administrative Controls Low on the hierarchy but very important Procedures, training, etc. Best used to compliment other measures Another building block, if you understand the hazards, you can start to design controls for them. Gets people involved and talking. Used to compliment other safeguards/explain procedures

Personal Protective Equipment Safety glasses Hearing protection Safety boots Gloves Respirators

Risk Assessment Review What triggers a review? Injury? Near Miss? OR Set Cycle? Movement of Equipment? Another building block, if you understand the hazards, you can start to design controls for them. Gets people involved and talking. Used to compliment other safeguards/explain procedures

Proactive Machine Safety Working towards zero injuries or incidents Establishment of Baseline Engagement of employees Establishment of metrics Continuous Improvement!

Machine Safety Programs Determine Projects Determine Effort and Resources Assign Resources

Why they struggle They don’t understand the scope of what needs to be done Don’t recognize all the hazards Don’t have a good understanding of all the machines they have and the state they are in Don’t have a timeline or plan or budget Just don’t know where to start

Why they struggle No risk assessment Identification of hazards Rating of hazards No team approach to risk assessment (particularly operator) Working from the bottom of hierarchy of controls CSA Z432 not considered when designing controls Process not considered when designing controls

Machine Hazard Audit Mention taking an inventory of machines, hazards

Policy/Procedure Review Lockout Program Emergency Response Program Preventative Maintenance Training Work Procedures Ergonomics

Engagement How do we get employees involved? How do we get their input? How do we get their acceptance?

5 Stages of Machine Safety Change Denial Anger Bargaining Sadness Acceptance

How to Engage? Involvement with the risk assessment. Involvement with selection of safeguard options. Review of design. Testing/Implementation Feedback

Measurement Reactive Measurement Proactive Measurement

Reactive Measurement Incident Rate Improvement Orders WCB Rate

Proactive Measurement Overall Risk Inspection Completion % Engineered Controls

Measurements

Continuous Improvement Inspections Review New projects Procurement

Procurement NEW MACHINES DON’T HAVE TO COME WITH GUARDING!!!

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