Machine Guarding - LO/TO

Transcription

1 Machine Guarding - LO/TO FPA Safety Conference January 2006 James Washam OSHA Region V

2 Amputations in Manufacturing Over 5,500 amputations per year and about 21 fatalities Over 40 % related to lo/to issues

3 In Top 10 Violations For Most Industries Control of hazardous energy General requirements for all machines Mechanical power- transmission apparatus.

4 Major Causes of Amputations Inadequate or non-existing existing safeguards. By-passing safeguards. Improperly Applied Safeguards. Failure to lockout or isolate energy.

5 OSHA s General Guarding Standard Types of guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks.

6 Safeguarding Section is a general machine guarding standard that applies to all machinery not otherwise covered by Subpart O. The guarding required must be provided by a "device" that does not allow reliance upon the skill or attentiveness of employees. It is "intended to eliminate danger from unsafe operating procedures, poor training or employee inadvertence

7 WHERE MECHANICAL HAZARDS OCCUR Point of operation Power transmission apparatus Other moving parts Nip points Pinch points Shear points Rotating parts Flying parts

8 METHODS OF GUARDING Fixed Barrier (to prevent access to danger) Interlock Gates Adjustable Self-Adjusting Presence-Sensing (safety mats, light curtains) Safety Pull Cords Two-Hand Controls

9 Decisions Different Tasks Different Exposures Different Hazards Different Guarding Methods Now What?

10 Tasks Based Risk Assessment In order to provide adequate protection during production operations including and servicing and maintenance tasks, all tasks must be known and evaluated. Many machine hazards are being missed because task identification is not a part of the process

11 Extruder Tasks Cleaning Primer Rolls Web Up Breaker Plate Swap Rupture Disk Replacement Taping and Cleaning of Laminator Nip Rolls Unloading of Finished Roll Stock at Winder. Loading / Unloading of Secondary Unwind Roll Stock.

12 Aquaflex Pilot Flexo Press Tasks Loading/unloading a roll of substrate in the unwind section. Splicing Webbing Corona Treatment Changing Doctor Blade Changing press components in the flexo decks and Gravure deck including rolls, cylinders, plates, ink metering system, etc.

13 Aquaflex Pilot Flexo Press Tasks Making Gravure Doctor Blade Adjustment while printing Setting up of the press lamination operation Assembling and dissembling the die stations Collecting samples from the stacking table Unloading a roll of finished substrates from the rewinder Running the press

14 An overview of the steps in Task-Based Risk Assessment and Reduction 1. Determine the limits of the machine. 2. Determine the tasks to be performed over the life-cycle of the machine. 3. Identify the hazards associated with these tasks and rate their severity.

15 An overview of the steps in Task-Based Risk Assessment and Reduction 4. For each hazard, establish the probability of a hazardous event. 5. Determine the level of risk. If it is not tolerable - continue...

16 An overview of the steps in Task-Based Risk Assessment and Reduction 6. Eliminate the hazard or reduce its severity. (lessen energy or toxicity) 7. Determine the appropriate type and minimum required level of performance of protective (safeguarding) measures to provide the desired degree of risk reduction, using the Safety Hierarchy as a guide.

17 Hierarchical of Protective Measures Eliminate the hazard Apply safeguards Administrative controls

18 Guidance ANSI B11.TR Risk Assessment and Risk Reduction

19 Safeguarding Flexo-Presses Extrusion- Coating

20 Biggest Issue In - Running Nip Points

21 Nip Points Extrusion Coating Laminating Station

22 Extrusion Rewind Nips

23 Nip Points Extrusion Laminating Station

24 Winder

25 Nip Points Extrusion Coating Laminating Station

26

27 Fixed Nip Guard

28 Shapes of Nip Guards

29 Presence Sensing Devices Safety Mat

30 Carton Folder, Gluer and Cutting Operation

31 Area Scanners

32 Movable Guards with Interlocks prevents contact with horizontal movement of hydraulic screen changer Allows electrical system to permit machine operation Actuated when guarding is closed or opened Prevents movement when the operator is exposed to hazard Electrical Interlock Switch

33 Interlocked Guard in-running nip of the chill rolls Emergency stop pull cable Electrical Interlock Switch

34 Pull-Roll Nips Sturdy metal mesh in guard emergency stop pull cord

35 Trim Knives trim knife pivoting blade guard

36 Finishing Blade Guard

37 Pressroom Safety IP Aquaflex Producer 6-color Flexo Press with 1 Gravure Station, die cut and sheeter w/high speed stacking table or roll to roll capability.

38 Pressroom Safety Sensors Guards Door interlocks Safety stickers Cut resistant gloves Rated hoists and lift devices Fire suppression E-Stops (emergency stops) Main cut off switches Clear access to equipment

39 Guarded 10 Color Flexo - Press

40 Sensors Unwind and Rewind Stands Latch open (top down view), NO CONTACT between sensor and latch press will not start. Sensor not satisfied Latch closed, CONTACT MADE between latch and sensor - sensor satisfied

41 Guards and Interlocks Deck guard When in place protects fingers from NIP points during operation Deck Guard interlock must be in place to operate the press When guard is in place the interlock pin,, inserts into the interlock device

42 Guards Flexo Print Station Stainless steel guard prevents fingers from coming in contact with plate cylinder and anilox roll during press operation

43 Guards In-feed Nip Rollers Plexiglass door guard to keep hands away from Pinch Points and still allow visibility during operation.

44 Press Interlocks Interlock device on all guards Interlock connection pin on guard door. Pin must plug into press interlock to insure guard is in place before operation

45 Guards Film Treater Doors must be closed in order for treater to come on Interlocks must make connection to allow film treater to operate

46 Gravure Station Plexiglass Doors with interlocks. (Metal pins are located on the guard door and the safety interlock is mounted on the deck frame)

47 Gravure Station (solvent Inks) CO2 fire suppression system Ink Kit grounding wires The gravure deck is also equipped with explosion proof motors and ink mixers. (All motors and wires with in an 8 window of the gravure deck are explosion proof. This allows solvent ink to be used in the gravure section).

48 Stacker Table When table is pulled into position, interlock must be satisfied Sheeter interlock

49 Doctor Blades Stainless steel doctor blades are in effect large razor blades and are very sharp, use cut resistant gloves when handling them.

50 Controlling Hazardous Energy. Lockout/ Lockout/tagouttagout

51 Purpose: LO/TO 1.Prevent injury from the unexpected startup or release of stored energy. 2.Reduce the number of fatalities and injuries. 3.Establish a program and procedures for controlling hazardous energy.

52 Major provisions of lockout program: 1. Machine Procedures 2. Training and Retraining 3. Audits

53 Types of Energy: Mechanical Chemical Pneumatic Electrical Hydraulic Gravity Thermal

54 Important Definitions: Servicing and/or maintenance where employees may be exposed to unexpected start-up or release of hazardous energy: Constructing Installing and setting up Adjusting, inspecting, modifying Lubricating, cleaning or un-jamming Tool changes

55 Definitions (cont d) Energy Isolation Devices: A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following: A manually operated electrical circuit breaker; a disconnect switch; a manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors.

56 Definitions (cont d) Energy Isolation Devices: Push buttons, selector switches and other control circuit type devices are not energy isolating devices

57 3 LO/TO Situations: 1. Normal/major maintenance, machine shut down. 2. Servicing and maintenance that takes place during production. LOTO applies if guards are removed, by- passed or operator has to place body in danger zone.

58 3. Minor servicing and maintenance under the exception: Has to take place during normal production operations (set-up?). Has to be routine, repetitive and integral to the production process. Alternative effective protection must be provided.

59 Alternative effective protection such as: Remote lubricators or other remote devices Interlocked gates and barriers Mechanical blocks, pins, bars, or locking devices

60 OSHA s letters of interpretation 1992 and 2004 related to minor servicing and alternative protection for printing industry - summary In the printing industry, we understand that the term "minor servicing" includes,among others, tasks such as clearing of certain types of paper jams; minor cleaning,, lubricating and adjusting operations; certain plate and blanket changing tasks; and, in some cases, paper webbing and paper roll changing.

61 Letters (cont d) One such method of effective alternative protection is the inch-safe safe-service service technique for the main drive control (see ANSI B65.1 and B65.2) Employers may use a combination of guarding methods, safe work practices and inch-safe safe-service service methods. Under no circumstances can an employee reach into danger area while equipment is running or energized.

62 Example: Minor Servicing While printing 10 million copies of TV guide, 10 or 15 times a shift, a minor paper jam occurs, hickies pop up, the operator raises and interlocked gate guard, which stops machine movement. The task is taking place during normal production operations, appears to be routine, repetitive and integral to the production process and alternative effective protection is provided by the interlocked guard.

63 Trim Knives Adjusted Changed

64 Power-Positioned Positioned Trim Knives

65 What About Roll Cleaning? Is it minor servicing? Can it be performed with power off and locked out? What alternative protection can be used?

66 Roll Cleaning? If power is needed, can the rolls be opened far enough to eliminate hazard? Can the rolls be cleaned from the out-going nip side? Can a nip guard and a cleaning tool be used?

67 Roll Cleaning Can a combination of guarding and inch-safe safe-service service method be used? Can automatic roll cleaning devices be used?

68 Power shut off boxes Separate shut off s. The press is divided into sections for ease of maintenance. Each section of press can be individually shut down for safety and maintenance.

69 References for Machine Safety: ANSI Standards B65.1 (2005) B11.TR Risk Assessment B Performance Criteria for Safeguarding NFPA Electrical Standard for Industrial Machinery ANSI/SPI B Plastics Machinery - Plastics Extrusion Machines - Requirements for the Manufacture, Care and Use Gov

70 Questions?