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04/21/23Industrial Safety Lecture Four1
Safe Materials Handling and Safe Materials Handling and Machine SafetyMachine Safety
Joe Nail
04/21/23Industrial Safety Lecture Four2
Introduction Introduction
Handling Materials SafelyHandling Materials Safely
50 tons per one ton shipped.50 tons per one ton shipped. Some is moved by machine and some by hand.Some is moved by machine and some by hand. When handling material, technique is everything.When handling material, technique is everything.
04/21/23Industrial Safety Lecture Four3
Causes of InjuriesCauses of Injuries
25% of all injuries are related to material 25% of all injuries are related to material handling.handling.
80% are to the lower back.80% are to the lower back. Incorrect lifting causes most injuries.Incorrect lifting causes most injuries. Incorrect use of equipment.Incorrect use of equipment.
04/21/23Industrial Safety Lecture Four4
CarelessnessCarelessness Be aware of your environment.Be aware of your environment.
Hey Charlie! Did you see that game last night?
04/21/23Industrial Safety Lecture Four5
Avoiding Workplace Injuries Avoiding Workplace Injuries
Stay in shape.Stay in shape.
Consider where you will walk.Consider where you will walk. Don’t use your body if you don’t have to.Don’t use your body if you don’t have to.
04/21/23Industrial Safety Lecture Four6
Rules for LiftingRules for Lifting
Get close to the load.Get close to the load. Keep feet apart.Keep feet apart. Keep back straight.Keep back straight. Bend your knees.Bend your knees. Tuck your chin.Tuck your chin.
Grip the load with your palms.Grip the load with your palms.
04/21/23Industrial Safety Lecture Four7
Hazards Associated with Hazards Associated with Materials HandlingMaterials Handling
Check your environment for sufficient Check your environment for sufficient moving roommoving room
Check for projecting objects, wear gloves.Check for projecting objects, wear gloves. Are materials secure?Are materials secure? Are chemicals to be moved?Are chemicals to be moved?
04/21/23Industrial Safety Lecture Four8
Teamwork and Handling Teamwork and Handling Various Shapes and SizesVarious Shapes and Sizes
If an object seems to heavy to lift, it If an object seems to heavy to lift, it probably is.probably is.
When working with others, When working with others, communication is critical.communication is critical.
Your back should be kept straight when Your back should be kept straight when you carry objects.you carry objects.
Special lifting tools should be sought out Special lifting tools should be sought out and used for large objects.and used for large objects.
Protect yourself when handling things.Protect yourself when handling things.
04/21/23Industrial Safety Lecture Four9
Examples of Lifting EquipmentExamples of Lifting Equipment
04/21/23Industrial Safety Lecture Four10
Hand Tools and AccessoriesHand Tools and Accessories
04/21/23Industrial Safety Lecture Four11
Power Operated Hand TrucksPower Operated Hand Trucks
Examples of a “walkie” and a “rider” type powered hand trucks
04/21/23Industrial Safety Lecture Four12
Powered Industrial trucksPowered Industrial trucks
Trucks are usually classified by power Trucks are usually classified by power source.source.
Electric MotorsElectric Motors Internal Combustion EngineInternal Combustion Engine
– GasolineGasoline– DieselDiesel– LP Liquefied PetroleumLP Liquefied Petroleum
04/21/23Industrial Safety Lecture Four13
Standard Powered Industrial Standard Powered Industrial Lift TruckLift Truck
04/21/23Industrial Safety Lecture Four14
Straddle TruckStraddle Truck
04/21/23Industrial Safety Lecture Four15
Order Picker TruckOrder Picker Truck
04/21/23Industrial Safety Lecture Four16
Industrial Truck SafetyIndustrial Truck Safety Popular Misconceptions Popular Misconceptions“Anyone can drive a lift truck.”Anyone can drive a lift truck.” ““They handle just like a car.”They handle just like a car.” ““They are easier to drive than a car.”They are easier to drive than a car.” ““You don’t need any training to safely You don’t need any training to safely
drive a fork lift.”drive a fork lift.”
04/21/23Industrial Safety Lecture Four17
Industrial Truck SafetyIndustrial Truck SafetyFactsFacts The center of gravity of a lift truck The center of gravity of a lift truck
changes.changes. Most trucks are “rear steer.”Most trucks are “rear steer.” Most trucks have no suspension system.Most trucks have no suspension system. It is NOT safe to alter the lift truck’s It is NOT safe to alter the lift truck’s
counterweight!counterweight!
04/21/23Industrial Safety Lecture Four18
Industrial Truck SafetyIndustrial Truck Safety
What does OHSA say about powered What does OHSA say about powered industrial truck training?industrial truck training?
OSHA regulations state that “only OSHA regulations state that “only trained and authorized operators shall trained and authorized operators shall be permitted to operate a powered be permitted to operate a powered industrial truck.”industrial truck.”
But why?But why?
04/21/23Industrial Safety Lecture Four19
Get the picture?Get the picture?
Training helps to Prevent Accidents!Training helps to Prevent Accidents!
04/21/23Industrial Safety Lecture Four20
Data plate.
Powered Industrial Trucks -Powered Industrial Trucks -Operator TrainingOperator Training
1910.178 (l)1910.178 (l)1915.120 (a)1915.120 (a)1917.1 (a)(2)(xiv)1917.1 (a)(2)(xiv)1918.1 (b)(10)1918.1 (b)(10)1926.602 (d)1926.602 (d)
22
DisclaimerDisclaimerThis presentation is intended as a resource for
providing training on OSHA’s revised powered industrial truck operator standards. It is not a substitute for any of the provisions of the Occupational Safety and Health Act of 1970, or for any standards issued by the U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA). It is also not a substitute for a powered industrial truck operator training program.
23
AcknowledgmentAcknowledgment OSHA’s Office of Training and Education wishes to
acknowledge the following for contributing some of the graphics used in this presentation:– Caterpillar Lift Trucks– Mason Contractors Association of America– Industrial Truck Association– State of Utah Labor Commission - Occupational Safety &
Health Division – Steamship Trade Association of Baltimore– Taylor Machine Works, Inc.– UAW - Ford National Joint Committee on Health and Safety
Appearance of products does not imply endorsement by the U.S. Department of Labor.
24
Powered IndustrialPowered IndustrialTruck - DefinitionTruck - Definition
A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials. [American Society of Mechanical Engineers (ASME) definition]
Excluded are vehicles used for earth moving and over-the-road hauling.
Commonly known as forklifts, pallet trucks, rider trucks, forktrucks, or lifttrucks.
Can be powered through electric or combustion engines.
25
Scope of StandardScope of Standard
The scope provisions of 1910.178(a), which are based on ANSI B56.1 - 1969, remain in effect and cover:– ... fork trucks, tractors, platform lift trucks,
motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines.
– It does not apply to compressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, nor vehicles intended primarily for earth moving or over-the-road hauling.
This scope covers general industry, construction and shipyards.
26
Scope of Standard Scope of Standard (continued)(continued)
For marine terminal and longshoring industries, all powered industrial trucks are covered, no matter what specialized name they are given.
This includes, but is not limited to, straddle carriers, hustlers, toploaders, container reach stackers, and other vehicles that carry, push, pull, lift, or tier loads.
27
Reasons for New StandardReasons for New Standard
Powered industrial truck accidents cause approximately 100 fatalities and 36,340 serious injuries in general industry and construction annually.
It is estimated that 20 - 25% of the accidents are, at least in part, caused by inadequate training.
28
Additional Reasons for New Additional Reasons for New StandardStandard
Updated consensus standards have been published.
OSHA has been petitioned to improve the requirements for industrial truck training.
Advisory Committee on Construction Safety and Health has recommended improving the standard.
Resolutions have been introduced in the Senate and House urging OSHA to revise its outdated standard.
29
Forklift Fatalities, 1992-1996Forklift Fatalities, 1992-1996
Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts
86 89
120
95
114
1992 1993 1994 1995 1996
30
Forklift Fatalities by Age GroupForklift Fatalities by Age Group1992 -19961992 -1996
3%
10%
22%
21%
12%
5%
27%
Under 20
20 - 24
25 - 34
35 - 44
45 - 54
56 - 64
65 & over
Source: Bureau of Labor Statistics
31
Industries Where Powered Industrial Industries Where Powered Industrial Truck Accidents OccurredTruck Accidents Occurred
Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic andMechanical Engineering Safety Standards.
32Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.
Nonfatal Occupational Injuries and Nonfatal Occupational Injuries and Illnesses by Source, 1996Illnesses by Source, 1996
33
BackgroundBackground
The previous OSHA standards, while requiring operator training, did not define the type of training or authorization required.
March 15, 1988 - Industrial Truck Association (ITA) petitioned OSHA for specific training requirements.
34
Background Background (continued)(continued)
American National Standards Institute (ANSI), in cooperation with ASME, has revised its standard 4 times, including current lifttruck technology and specific training topics.
35
Background Background (continued)(continued)
OSHA published a proposed ruling on March 14, 1995 for General Industry, Shipyard, Marine Terminals, and Longshoring regulations, adding specific training requirements.
On January 30, 1996, OSHA proposed a revision of the construction standards, mandating the development of an operator training program based on the prior knowledge and skills of the trainee and requiring a periodic evaluation.
36
Final RuleFinal RuleOSHA published the final rule for Powered
Industrial Truck Operator Training on December 1, 1998.
The effective date is March 1, 1999. Start-up dates are included in paragraph (l)(7).
It applies to all industries except agricultural operations.
OSHA estimates that the new rule will prevent 11 deaths and 9,422 injuries per year.
37
Fatalities/Injuries Potentially Averted Fatalities/Injuries Potentially Averted Annually by New StandardAnnually by New Standard
Source: U.S. Department of Labor, OSHA, Office of Regulatory Analysis, 1997
38
Performance-Oriented Performance-Oriented RequirementsRequirementsThe powered industrial truck operator
training requirements are performance-oriented to permit employers to tailor a training program to the characteristics of their workplaces and the particular types of powered industrial trucks operated.
39
Revised Operator Training Revised Operator Training RequirementsRequirements General Industry: 1910.178 is amended by
revising paragraph (l) and adding Appendix A. Shipyard Employment: New section 1915.120 and
Appendix A are added. Marine Terminals: Section 1917.1 is amended by
adding new paragraph (a)(2)(xiv) and Appendix A. Longshoring: Section 1918.1 is amended by
adding new paragraph (b)(10) and Appendix A. Construction: 1926.602 is amended by adding new
paragraph (d) and Appendix A.
40
Operator TrainingOperator TrainingSafe operations
– The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by successful completion of the training and evaluation specified in the OSHA standard.
– Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the required training (or previously received appropriate training).
41
Training Program Training Program ImplementationImplementationTrainees may operate a powered industrial
truck only:– Under direct supervision of a person who
has the knowledge, training, and experience to train operators and evaluate their competence; and,
– Where such operation does not endanger the trainee or other employees.
42
Training Program Implementation (continued)
Training shall consist of a combination of:Training shall consist of a combination of: Formal instruction (e.g., lecture, discussion, Formal instruction (e.g., lecture, discussion,
interactive computer learning, written material), interactive computer learning, written material), Practical training (demonstrations and exercises Practical training (demonstrations and exercises
performed by the trainee), and performed by the trainee), and Evaluation of the operator’s performance in the Evaluation of the operator’s performance in the
workplaceworkplace
43
Training Program Training Program Implementation Implementation (continued)(continued)
Training and evaluation shall be conducted by a person with the knowledge, training and experience to train powered industrial truck operators and evaluate their competence.
44
Training Program ContentTraining Program ContentOperators shall receive initial training in
the following topics, except in topics which the employer can demonstrate are not applicable to safe operation in the employer’s workplace. – Truck-related topics– Workplace-related topics– The requirements of the standard
45
Training Program Content Training Program Content (continued)(continued)
– Operating instructions, warnings and precautions
– Differences from automobile
– Controls and instrumentation
– Engine or motor operation– Steering and maneuvering– Visibility
Truck-related topics– Fork and attachment
adaptation, operation, use – Vehicle capacity and stability– Vehicle inspection and
maintenance that the operator will be required to perform
– Refueling/Charging/ Recharging batteries
– Operating limitations– Other instructions, etc.
46
Training Program Content Training Program Content (continued)(continued)
– Surface conditions
– Composition and stability of loads
– Load manipulation, stacking, unstacking
– Pedestrian traffic
– Narrow aisles and restricted areas
– Operating in hazardous (classified) locations
– Operating on ramps and sloped surfaces
– Potentially hazardous environmental conditions
– Operating in closed environments or other areas where poor ventilation or maintenance could cause carbon monoxide or diesel exhaust buildup
Workplace-related topics
47
Training Program Content Training Program Content (continued)(continued)
The requirements of the OSHA standard on powered industrial trucks must also be included in the initial operator training program.
48
Refresher Training and Refresher Training and EvaluationEvaluationRefresher training, including an evaluation of the
effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.
Refresher training required when:– Unsafe operation – Accident or near-miss– Evaluation indicates need– Different type of equipment introduced – Workplace condition changes
49
Refresher Training and Refresher Training and Evaluation Evaluation (continued)(continued)An evaluation of each powered industrial
truck operator’s performance must be conducted:– After initial training,– After refresher training, and– At least once every three years
50
Avoidance of Duplicative Avoidance of Duplicative TrainingTrainingIf an operator has previously received
training in a topic specified in this section, and the training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely.
51
CertificationCertification
The employer shall certify that each operator has been trained and evaluated as required by the standard.
Certification shall include:– Name of operator– Date of training– Date of evaluation– Identity of person(s) performing the training
or evaluation
52
DatesDates The employer shall ensure that operators of
powered industrial trucks are trained, as appropriate, by the dates shown in the following table.
If the employee was hired:
The initial training and evaluation of that employee must be completed:
Before December 1, 1999
By December 1, 1999
After December 1, 1999Before the employee is assigned to operate a powered industrial truck.
53
Appendix A - Stability of Powered Appendix A - Stability of Powered Industrial TrucksIndustrial Trucks
Appendix A provides non-mandatory guidance to assist employers in implementing the standard.
This appendix does not add to, alter, or reduce the requirements of this section.
54
Appendix A - Stability of Powered Appendix A - Stability of Powered Industrial TrucksIndustrial Trucks
Definitions General Basic Principles Stability Triangle Longitudinal
Stability Lateral Stability Dynamic Stability
55
A
B
C
Vehicle Center ofGravity (Unloaded)
Center of Gravityof Vehicle and Maximum Load(Theoretical)
Stability Triangle - Figure 1
Notes:1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C.
Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C.
2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally.
56
Load CG
Vertical StabilityLine(Line of Action)
Combined CG
Truck CG
Load CG
Combined CG
Vertical StabilityLine(Line of Action)
Truck CG
The vehicle is stable This vehicle is unstable and will continue to tip over
Stability Triangle - Figure 2
57
Effective Powered Industrial Effective Powered Industrial Truck Operator Training ProgramTruck Operator Training Program
Four major areas of concern must be addressed:– The general hazards that apply to the operation
of all or most powered industrial trucks;
– The hazards associated with the operation of particular types of trucks;
– The hazards of workplaces generally; and,
– The hazards of the particular workplace where the vehicle operates.
58
Types of Powered Industrial Types of Powered Industrial TrucksTrucks There are many different types of powered industrial
trucks covered by the OSHA standard. Commonly used types include:
– High lift trucks, counterbalanced trucks, cantilever trucks, rider trucks, forklift trucks, high lift trucks, high lift platform trucks, low lift trucks, motorized hand trucks, pallet trucks, straddle trucks, reach rider trucks, high lift order picker trucks, motorized hand/rider trucks, and counterbalanced front/side loader lift trucks.
A single type of truck can only be described by calling it by all of its characteristics, (e.g., a high lift, counterbalanced, sit down rider truck).
59
Unique Characteristics of Unique Characteristics of Powered Industrial TrucksPowered Industrial Trucks
Each type of powered industrial truck has its own unique characteristics and some inherent hazards.
To be effective, training must address the unique characteristics of the type of vehicle the employee is being trained to operate.
60
Components of a Forklift Truck*Components of a Forklift Truck*
*One of the most common types of powered industrial trucks
61
Classes of Commonly-Used Classes of Commonly-Used Powered Industrial Trucks*Powered Industrial Trucks*
The Industrial Truck Association has placed powered industrial trucks into 7 classes.– Class I - Electric motor rider trucks– Class II - Electric motor narrow aisle trucks– Class III - Electric motor hand trucks or hand/rider trucks– Class IV - Internal combustion engine trucks
(solid/cushion tires)– Class V - Internal combustion engine trucks (pneumatic
tires)– Class VI - Electric and internal combustion engine
tractors– Class VII - Rough terrain forklift trucks
* Note that this classification refers to commonly-used vehicles and does not include all powered industrial trucks covered by the OSHA standard.
62
Class I - Electric Motor Rider Class I - Electric Motor Rider TrucksTrucksCounterbalanced rider type, stand upThree wheel electric trucks, sit-downCounterbalanced rider type, cushion tires,
sit-down (high and low platform)Counterbalanced rider, pneumatic tire, sit-
down (high and low platform)
63
Class I - Electric Motor Rider Class I - Electric Motor Rider TrucksTrucks
64
Class I - Electric Motor Rider Class I - Electric Motor Rider TrucksTrucks
Counterbalanced Rider Type, Stand-Up
65
Class II - Electric Motor Narrow Class II - Electric Motor Narrow Aisle TrucksAisle Trucks
High lift straddleOrder pickerReach type outriggerSide loaders, turret trucks, swing mast and
convertible turret/stock pickersLow lift pallet and platform (rider)
66
Class II - Electric Motor Narrow Aisle Class II - Electric Motor Narrow Aisle Trucks Trucks
67
Class II - Narrow Aisle Trucks Class II - Narrow Aisle Trucks
68
Class III - Electric Motor Hand or Class III - Electric Motor Hand or Hand/Rider TrucksHand/Rider Trucks
Low lift platformLow lift walkie palletReach type outriggerHigh lift straddleHigh lift counterbalancedLow lift walkie/rider pallet
69
Class III - Electric Motor Hand Class III - Electric Motor Hand or Hand/Rider Trucksor Hand/Rider Trucks
70
Class III - Hand & Hand/Rider Class III - Hand & Hand/Rider TrucksTrucks
71
Class IV - Internal Combustion Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Engine Trucks - Cushion (Solid) TiresTires
Fork, counterbalanced (cushion/solid tires)
72
Class IV - Internal Combustion Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Engine Trucks - Cushion (Solid) TiresTires
73
Class V - Internal Combustion Class V - Internal Combustion Engine Trucks - Pneumatic TiresEngine Trucks - Pneumatic Tires
Fork, counterbalanced (pneumatic tires)
74
Class V - Internal Combustion Class V - Internal Combustion Engine Trucks (Pneumatic Tires)Engine Trucks (Pneumatic Tires)
75
Class VI - Electric & Internal Class VI - Electric & Internal Combustion Engine TractorsCombustion Engine Tractors
Sit-down rider
76
Class VII - Rough Terrain Forklift Class VII - Rough Terrain Forklift TrucksTrucks
– Straight-mast forklift – Extended-reach forklift
All rough terrain forklift trucks
77
Rough Terrain Straight Mast Rough Terrain Straight Mast ForkliftsForklifts
78
Rough Terrain Extended-Reach Rough Terrain Extended-Reach ForkliftsForklifts
79
Some Types of Powered Industrial Some Types of Powered Industrial Trucks Used in MaritimeTrucks Used in Maritime
– Container top handlers
– Container reach stackers
– Straddle carriers
– Semi-tractors/ Utility vehicles
– Sidehandlers
– Combination vacuum lifts
– Yard tractors
The following types of vehicles are covered by the OSHA standard if the vehicles carry, push, pull, lift, or tier
loads.
80
Powered Industrial Trucks Used Powered Industrial Trucks Used in Maritimein Maritime
Container Handlers
81
Powered Industrial Trucks Used in Powered Industrial Trucks Used in MaritimeMaritime
Empty-Container Handler
82
Powered Industrial Trucks Used Powered Industrial Trucks Used in Maritimein Maritime
Container Reach Stacker
83
Powered Industrial Trucks Used Powered Industrial Trucks Used in Maritimein Maritime
Straddle Carriers
84
Powered Industrial Trucks Used Powered Industrial Trucks Used in Maritimein Maritime
Yard Tractor
04/21/23Industrial Safety Lecture Four85
Dock SafetyDock Safety
Painting of area.Painting of area. Trailer brakes and securing.Trailer brakes and securing. People in the area.People in the area. Perform daily check of truck.Perform daily check of truck.
04/21/23Industrial Safety Lecture Four86
Dock SafetyDock Safety
Portable Docking PlatePortable Docking Plate
04/21/23Industrial Safety Lecture Four87
Dock SafetyDock Safety
Dock Restraint MechanismDock Restraint Mechanism
04/21/23Industrial Safety Lecture Four88
ConveyorsConveyors
04/21/23Industrial Safety Lecture Four89
ConveyorsConveyors
Powered type is most dangerous.Powered type is most dangerous. Most people get hurt while working on Most people get hurt while working on
them.them. Most injuries involve fingers, hands, Most injuries involve fingers, hands,
and arms.and arms. Accidents can be prevented if workers Accidents can be prevented if workers
are careful to turn off the power and are careful to turn off the power and lock it out.lock it out.
04/21/23Industrial Safety Lecture Four90
Hoists and Hoists and CranesCranes
04/21/23Industrial Safety Lecture Four91
Hoists and Hoists and CranesCranes
04/21/23Industrial Safety Lecture Four92
Hoists and CranesHoists and Cranes
Hoists and Cranes should be inspected Hoists and Cranes should be inspected before use, every time.before use, every time.
When cranes fail, it usually happens When cranes fail, it usually happens fastfast.
Tension on a sling is relative to total Tension on a sling is relative to total weight be lifted and angle of sling.weight be lifted and angle of sling.
Never stand under a suspended load.Never stand under a suspended load.
04/21/23Industrial Safety Lecture Four93
Receiving and Storing Receiving and Storing MaterialsMaterials
Does this look safe to you?Does this look safe to you?
04/21/23Industrial Safety Lecture Four94
When Storing MaterialsWhen Storing Materials
Place large, heavy packages on the bottom Place large, heavy packages on the bottom and lighter ones on top.and lighter ones on top.
Never place materials where they can be Never place materials where they can be tripped over or where someone could get hurt tripped over or where someone could get hurt attempting to retrieve them.attempting to retrieve them.
When materials are moved to where you are When materials are moved to where you are working, they should be secured so they can’t working, they should be secured so they can’t fall on anyone.fall on anyone.
Never block a traffic path or prop materials Never block a traffic path or prop materials up against a wall where they might slide over up against a wall where they might slide over and cause an accident.and cause an accident.
04/21/23Industrial Safety Lecture Four95
Corrosive and Flammable Corrosive and Flammable LiquidsLiquids Understand what it is that you are about Understand what it is that you are about
to move.to move. Examine the containers to make sure Examine the containers to make sure
they are sealed and properly labeled.they are sealed and properly labeled. Make sure you are wearing all required Make sure you are wearing all required
PPE.PPE.
04/21/23Industrial Safety Lecture Four96
Safety GuardsSafety Guards
04/21/23Industrial Safety Lecture Four97
Safety GuardsSafety Guards
Are required to prevent accidents.Are required to prevent accidents. Protect people, not the machine.Protect people, not the machine. Hazardous parts include point of Hazardous parts include point of
operation components, control operation components, control mechanisms, parts that transmit power, mechanisms, parts that transmit power, and parts that retain stored energyand parts that retain stored energy
04/21/23Industrial Safety Lecture Four98
Moving Parts Moving Parts Make Make Guards Guards NecessaryNecessary
04/21/23Industrial Safety Lecture Four99
Moving Parts Moving Parts Make Guards Make Guards NecessaryNecessary
04/21/23Industrial Safety Lecture Four100
Point of Operation GuardPoint of Operation Guard
OSHA 29 CFR 1910.217OSHA 29 CFR 1910.217
04/21/23Industrial Safety Lecture Four101
Fixed GuardsFixed Guards
04/21/23Industrial Safety Lecture Four102
Fixed GuardsFixed Guards
Prevent entry into the Prevent entry into the point of operationpoint of operation Do not move when the machine is in Do not move when the machine is in
operation.operation. Example: Barrier GuardExample: Barrier Guard Example: Enclosure GuardExample: Enclosure Guard
04/21/23Industrial Safety Lecture Four103
Interlocking GuardsInterlocking Guards
Used when a fixed guard cannot be Used when a fixed guard cannot be used.used.
Connected to machine controls or power Connected to machine controls or power source.source.
Can be mechanical, electrical, or Can be mechanical, electrical, or pneumatic.pneumatic.
04/21/23Industrial Safety Lecture Four104
Automatic GuardsAutomatic Guards Push, pull, or sweep the operator’s Push, pull, or sweep the operator’s
hands out of the danger zone.hands out of the danger zone. Example: Automatic Pull BacksExample: Automatic Pull Backs
04/21/23Industrial Safety Lecture Four105
Presence-sensing GuardsPresence-sensing Guards
No physical barrier.Create a sensing No physical barrier.Create a sensing area around the danger zone.area around the danger zone.
May use magnetic fields, radio waves, or May use magnetic fields, radio waves, or light waves.light waves.
Machinery must be able to stop Machinery must be able to stop instantaneouslyinstantaneously.
04/21/23Industrial Safety Lecture Four106
Power Transmission GuardsPower Transmission Guards Prevent pieces from flying out.Prevent pieces from flying out. Should be kept in place at all times while the Should be kept in place at all times while the
machine is running.machine is running. Should only be removed for repair work.Should only be removed for repair work.
04/21/23Industrial Safety Lecture Four107
Other Safety DevicesOther Safety Devices
Machine controls.Feeding and extracting tools.Ejectors.
04/21/23Industrial Safety Lecture Four108
OSHA Lock Out/Tag Out OSHA Lock Out/Tag Out Procedures Procedures 29 CFR 1910.14729 CFR 1910.147 Locking out has to do with the removal or Locking out has to do with the removal or
prevention of hazardous energy.prevention of hazardous energy. Tag out is a communication technique that Tag out is a communication technique that
warns others of the machines repair work.warns others of the machines repair work.
109
Control of Hazardous EnergyControl of Hazardous Energy
29 CFR 1910.147 The standard covers the servicing and
maintenance of machines and equipment in which the unexpected energization or start up of the machines or equipment , or release of stored energy could cause injury to employees.
110
Provisions Of The StandardProvisions Of The Standard
Requires employers to establish procedures for isolating machines or equipment from their source of energy and affixing appropriate locks or tags to energy isolating devices
111
Employer ResponsibilitiesEmployer Responsibilities
Establish energy control programEstablish energy control procedures for
machines and equipmentProvide employee trainingConduct periodic inspections of the energy
control program
112
Application Of The StandardApplication Of The Standard
An employee is required to remove or bypass a guard or other safety device
An employee is required to place any part of their body in contact with the point of operation of the operational machine or piece of equipment
An employee is required to place any part of their body into a danger zone associated with a machine operating cycle
113
Work on cord and plug connected electric equipment controlled by unplugging of the equipment - the plug is under exclusive control of the employee performing maintenance
Exceptions To The StandardExceptions To The Standard
114
Hot tap operations involving transmission and distribution systems for substances such as gas, steam, water, or petroleum products
Exceptions To The StandardExceptions To The Standard
115
Minor Servicing TasksMinor Servicing Tasks
Employees performing minor tool changes and adjustments that are routine, repetitive, and integral to the use of the equipment and that occur during normal operations are not covered by the lockout/tagout standard, provided the work is performed using alternative measures that provide effective protection.
116
DefinitionsDefinitions
Authorized employee: A person who locks out or tags out machines or equipment in order to perform servicing or maintenance
Affected employee: A person whose job requires him to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout or tagout
117
DefinitionsDefinitions
Energy isolating device: The mechanism that prevents the transmission or release of energy and to which locks or tags are attached
Includes manually operated circuit breakers, disconnect switches, line valves, blocks, and others
118
Lockout: The placement of a lockout device on an energy isolating device to ensure that the equipment being controlled cannot be operated until the lockout device is removed
DefinitionsDefinitions
119
Tagout: The placement of a tagout device on an energy isolating device to indicate the equipment being controlled may not be operated until the tagout device is removed
DefinitionsDefinitions
120
Shut down the machine or equipment Isolate the machine or equipment from the
energy sources Apply the lockout or tagout device(s) to the
energy isolating device(s) Safely release all potentially hazardous
stored or residual energy Verify the isolation of the machine or
equipment prior to the start of servicing work
De-energizing EquipmentDe-energizing Equipment
121
Stored EnergyStored Energy
If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation shall be continued until the possibility of such accumulation no longer exists
122
Re-energizing EquipmentRe-energizing Equipment
Ensure that machine or equipment components are operationally intact
Ensure that all employees are safely positioned or removed from equipment
Ensure that lockout or tagout devices are removed from each energy isolation device by the employee who applied the device
123
Lockout/Tagout RequirementsLockout/Tagout Requirements
If an energy isolating device is not capable of being locked out, the employer’s energy control program shall utilize a tagout system
124
Lockout RequirementsLockout Requirements
After January 1990, whenever replacement, major repair, or modification of a machine is performed, or whenever new machines or equipment are installed, they must be designed to accept a lockout device
125
Device RequirementsDevice Requirements
Durable: Lockout and tagout devices must withstand the environment to which they are exposed for the maximum duration
Standardized: Both lockout and tagout devices must be standardized according to either color, shape, or size
Tagout devices must also be standardized according to print and format
126
Substantial: Lockout and tagout devices must be substantial enough to minimize early or accidental removal
Identifiable: Locks and tags must clearly identify the employee who applies them.
Device RequirementsDevice Requirements
127
Tags must also include a legend such as:– Do not start– Do not open– Do not close– Do not energize– Do not operate
Tag RequirementsTag Requirements
128
Periodic InspectionsPeriodic Inspections
The employer shall conduct a periodic inspection of the energy control procedure at least annually
Shall be performed by an authorized employee other than the person(s) utilizing the energy control procedure being inspected
129
Shall be conducted to correct any deviations or inadequacies identified
Where lockout is used, the inspection shall include a review between the inspector and each authorized employee
Periodic InspectionsPeriodic Inspections
130
Where tagout is used, the inspection shall include a review between the inspector and each authorized and affected employees
Periodic InspectionsPeriodic Inspections
131
The employer shall:– Certify that the periodic inspections have been
performed– Identify the machine or equipment on which
energy control procedures were used The employer shall also note:
– The date of the inspection– The employees included in the inspection– The person performing the inspection
Periodic InspectionsPeriodic Inspections
132
Training and CommunicationTraining and Communication
Each authorized employee shall receive training in:– Recognition of applicable hazardous
energy sources– Type and magnitude of the energy
available in the workplace– Methods and means necessary for energy
isolation and control
133
Each affected employee shall be instructed in the purpose and use of the energy control procedure
All other employees shall be instructed about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out
Training and CommunicationTraining and Communication
134
The employer shall certify that employee training has been accomplished and is being kept up to date
Certification shall contain employee names and dates of training
Training and CommunicationTraining and Communication
135
Group Lockout or TagoutGroup Lockout or Tagout
Primary responsibility is vested in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device
Each authorized employee shall affix a personal lockout or tagout device to the group lockout device
136
Outside PersonnelOutside Personnel
Whenever outside servicing personnel are engaged in activities covered by lockout/tagout, the on-site employer and the outside employer shall inform each other of their respective lockout or tagout procedures
137
Tagout TagsTagout Tags
138
Lockout DeviceLockout Device
139
Group LockoutGroup Lockout
140
Tagout TagTagout Tag
141
Lockout SignageLockout Signage
04/21/23Industrial Safety Lecture Four142
ReviewReview 1. What is the best way to avoid hurting yourself when moving material? 2. What is most dangerous when wearing gloves around rotating equipment? 3. Describe the best method for lifting. 4. What is the best way to carry a small box or carton? 5. What equipment can you use to move a barrel alone? 6. Describe how to handle moving a loaded hand truck down a ramp. 7. When is it permissible to ride on the platform of a moving truck? 8. What must be checked before entering a trailer on a shipping dock? 9. What is the best way to prevent accidents while working on conveyors? 10. What does the angle of a lifting sling have to do with the stress placed on it? 11. What is a pinch point? 12. What is meant by the term “point of operation”? 13. What word is used to mean a back and forth motion? 14. What is the correct spacing for a grinder wheel from the work rest? 15. What type of machine guard limits the operator’s access to the danger zone? 16. Which type of machine guard prevents access to the danger zone altogether? 17. What type of guard cannot be moved while the machine is running? 18. What type of guard, when removed, prevents the machine from running? 19. What type of guard physically pulls the operator out of the danger zone? 20. How fast should a machine stop when it is equipped with a presence sensing
guard?
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