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

2. 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

3. 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.

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

5. 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?

6. 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?

7. Proactive versus Reactive1.
An Injury Occurs 2.
An Improvement Order is Issued 3.
We Decide to be PROACTIVE

8. 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

9. 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

10. 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?

11. 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.

12. 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.

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

14. 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)

15. 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.

16. 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

17. 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

18. 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

19. 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

20. 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)

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

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

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

24. 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

25. 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

26. 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

27. 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

28. 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.

29. 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

30. 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

31. Personal Protective Equipment
Safety glasses
Hearing protection
Safety boots
Gloves
Respirators

32. 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

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

34. Machine Safety Programs
Determine Projects
Determine Effort and Resources
Assign Resources

35. 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

36. 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

37. Machine Hazard Audit
Mention taking an inventory of machines, hazards

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

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

40. 5 Stages of Machine Safety Change
Denial
Anger
Bargaining
Sadness
Acceptance

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

42. Measurement
Reactive Measurement
Proactive Measurement

43. Reactive Measurement
Incident Rate
Improvement Orders
WCB Rate

44. Proactive Measurement
Overall Risk
Inspection Completion
% Engineered Controls

45. Measurements

46. Continuous Improvement
Inspections
Review
New projects
Procurement

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

48. Your complete solution to production safety and performance
Questions?
Your complete solution to production safety and performance
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