GENERAL MOTORS COMPANY

Transcription

1 UAW-GM Safety System Audit Performance Standard PORTABLE POWER & MACHINE SHOP TOOLS Authorized By: Rick O Donnell, Assistant Director, UAW Ken Glass, Assistant Director, GM UAW-GM APS Revision 1 Date: May 6, Purpose The purpose of this standard is to establish the minimum requirements to control the potential hazards involving the use of portable power and machine shop tools to reduce the risk of injuries. 2.0 Scope This standard applies to all sites outlined in section 3.0 Scope in the General Requirements of the UAW-GM Safety System and where portable power and machine shop tools are used. This standard does not apply to contractors, where the nature of the construction or maintenance work requires that contractor employee s work in proximity to UAW-GM employees, GM will require, as a condition of the construction or maintenance contract, the contractor s commitment to abide by UAW-GM plant/site Health and Safety work Practices. Construction/installation/demolition, service providers, blanket purchase order, spot buy, and production contractors must meet or exceed regulatory requirements and contractual agreements. 3.0 Definitions Competent Person - A person with sufficient training, experience, knowledge and other qualities to enable him/her to properly undertake the duties assigned to him/her. Machine Hazard - Any hazardous energy on the machine that could cause injury to personnel (e.g., Mechanical, Electrical, Hydraulic, Pneumatic, Thermal, Radiation, Noise, Vibration, Gravity, Chemical and others). Machine Shop Tools The broad category of cutting tools includes all of the consumable tooling involved in milling, drilling, turning and other lathe and machining center operations. Drills, end mills, taps, grinders, powdered actuated tools, belt sanders, reamers and inserts are all included. Portable Power Tools Mobile tools that require a power source to operate. There are several types of portable power tools, based on the power source including electric, pneumatic, hydraulic, liquid fuel, powder actuated and battery (electrical) powered.

2 UAW-GM Safety System Audit Performance Standard Page 2 of Requirements 4.1 Planning Regulatory Compliance Each site must identify and comply with all applicable H&S regulatory requirements related to portable power and machine shop tools. These requirements must be part of the Regulatory Inventory as described in section of the UAW-GM Safety System Hazard Identification and Risk Assessment Each site must identify portable power and machine shop tools that are considered Critical Equipment as defined in section 2.4 of the UAW-GM Safety System. These tools must be part of the site s Critical Equipment Inventory. The following portable power and machine shop tools must be included as part of this inventory: Machine shop tools (e.g. lathes, mills, drill presses, grinders, belt sanders, power saws, etc.) Manual welding equipment Powdered activated tools Gas or compressed gas powered tools Compressed air tools (e.g. impact wrench, nail guns, etc.) Spindle guns (e.g. electric, pneumatic, hydraulic, etc.) High torque tools Hydraulic lifting equipment For all new, refurbished, relocated, or modified portable power and machine shop tools, each site must use the process outlined in the Safety Design & Launch Audit Performance Standard ( ) In addition, each site must comply with the GM Global Ergonomics Specification for Machinery and Equipment (outlined in section Hand and Power Hand Tools) for ergonomic related hazards. For each portable power and machine shop tool on the Critical Equipment Inventory, the site must identify the tasks for which these tools are utilized. Then conduct a risk evaluation to determine which of these tasks are considered Critical Tasks as outlined in section 2.3 of the UAW-GM Safety System. These Critical Tasks must be included on the site s Critical Tasks inventory. 4.2 Implementation Documented Program Each site must have a documented portable power and machine shop tool program that addresses, at a minimum, the following: Hazard Identification & Risk Assessment Process

3 UAW-GM Safety System Audit Performance Standard Page 3 of 9 Roles and responsibilities Development of SOPs or standardized work for the safe operation of portable power and hand tools Portable power and machine shop tool preventative maintenance process. Employee training Management of Change procedures Checking and Corrective Action requirements Roles & Responsibilities Site Senior Leader Assign a engineering or maintenance resources as the Portable Power and Machine Shop Tool Audit Performance Standard Champion Must adopt, support and enforce the requirements outlined in this standard with the goal of continuously improving portable power and machine shop tool safety at the site. Provide resources to control identified portable power and machine shop tool hazards and risks. Floor Operations Leadership Adhere to and follow the portable power and machine shop tool safety requirements outlined in this standard. Require and perform a documented hazard identification and risk assessment on all portable power and machine shop tools and follow the management of change process. Engage all workers in the reporting of portable power and machine shop tool hazards. Implement a daily pre-operation start up process for all portable power and machine shop tools to include safety inspections (where required). Replace damaged or faulty portable power and machine shop tools and/or taking portable power and machine shop tools out of service. Ensure that portable power and machine shop tools are properly maintained by instituting an inspection program. Ensure portable power and machine shop tools meet job requirements. Ensure employees are provided with information, training, instruction and supervision for the safe operation of portable power and machine shop tools. Production Workers Receive Safe Operating Practices (SOP) or standardized work training to use portable power and machine shop tools properly and in accordance with the manufacturer s instructions. Observe all safety precautions outlined in the SOP. Immediately report all matters which may affect workplace safety in relation to portable power and machine shop tools and associated systems of work to your Group leader or supervisor immediately. Perform daily pre-operation start up inspection on your portable power and machine shop tools (where required).

4 UAW-GM Safety System Audit Performance Standard Page 4 of 9 Site Maintenance / Global Facilities Leadership Primary responsibility to perform the hazard identification and risk assessment requirements (Section 4.1.2) Develop SOP (e.g. Safe Operating Practice, standardized work or maintenance job orders) that follow regulatory requirements and the requirements outlined in this standard. Require training for employees who use portable power or machine shop tools (Section 4.2.8) Site Maintenance Workers When performing maintenance or inspection on portable power and machine shop tools, always follow the energy control requirements outlined in the Hazardous/Lockout Energy Control Audit Performance Standard ( ). Always return portable power and machine shop tools to its designed and intended purpose prior to finishing a task, and verify safe guarding is functioning properly. Report damaged, faulty or malfunctioning portable power and machine shop tools to your Group leader or supervisor, and production immediately. Site H&S Resources Support the site in the identification and compliance with portable power and machine shop tool regulatory requirements (Section 4.1.1) Validate that floor operations leadership has performed a hazard identification and risk assessment process for all portable power and machine shop tools, and review documentation H&S Operating Practices (SOP) For each Critical Task identified in section the site must develop an SOP that includes the specific tool requirements outlined in section as well as the following minimum requirements: Ensure that portable power and machine shop tools are only used for the purpose in which they are designed for. Ensure that portable power and machine shop tools are operated, maintained and inspected in accordance with the manufacturer s operation manual (or where an operation manual is not available as per risk assessed). Ensure that damaged or faulty portable power and machine tools are reported to the relevant supervisor/manager immediately. Ensure that where there are changes to the work environment or work procedures, potential hazards are identified and risks assessed. Each SOP must be posted on the tool or provided in the worker s standardized work, and communicated to affected workers at least annually.

5 UAW-GM Safety System Audit Performance Standard Page 5 of Safety Requirements for Specific Tools Each site must incorporate the following safety requirements for specific tools into the day to day operations: Drill Presses Must be securely anchored to provide stability during operations Drill presses must be provided with an engineering control to prevent access to the rotating drill bit while the equipment is in motion. Never wear gloves, loose clothing, or jewelry while operating drill press. Wear protective hair covering to contain long hair. Do not place hands near the drill bit while operating. Always wear safety glasses while operating drill press. Securely bolt or clamp vise or work to table surface in at least two mounting locations. Do not remove safe guards and make sure safe guards are in place prior to use All Grinders Adequate guarding must be provided and remain in place that minimized exposure to pieces of wheel abrasives and product residues that may break off and create exposure Guarding must provide and maintain proper alignment with the wheel and allow for adjustments to be made to protect against flying particles, sparks or wheel fragments Guarding must be adjustable and be adjusted when the wheel diameter decreases. When the use of grinders has the potential to create an exposure to people, the site must perform an air sample to determine appropriate controls as outlined in the Chemical Exposure Assessment Audit Performance Standard Grinding wheels must be visually inspected and damaged or defective wheels replaced prior to use. Grinding wheels that are larger than 4 inches in diameter must be ring tested prior to installation and used within maximum operating speeds as determined by both the equipment and wheel manufacturers Pedestal Grinders Must be equipped with supportive rests that are: Rigid and designed to be adjusted to compensate for wheel wear Are kept adjusted within 1/8 inch of the wheel Are tightly secured after each adjustment Only adjusted when the wheel is not in motion and power has been terminated Must be equipped with tongue guards that are kept adjusted within 1/4 inch of the wheel

6 UAW-GM Safety System Audit Performance Standard Page 6 of 9 Must be securely anchored to provide stability during operations Portable Grinders Must only be operated with the guards in place and properly adjusted Must be marked to indicate appropriate wheel size Safety glasses must be worn at all times when in operation For hand held air grinders: Air hoses and hose/adaptor connections must be checked prior to use Air supply must be disconnected when changing wheels/cutters Abrasive Wheels Must be mounted between flanges that are not less than 1/3 inch the diameter of the wheel. Flanges must be checked prior to use to ensure that they are not worn, warped or sprung. Maximum spindle speeds must be checked prior to mounting the wheels Spindle/Torque Guns All rotating powered hand tools must have engineering controls provided with mutilation/safety socket covers, rubber guards/boots, spindle covers or spindle sleeves to protect the worker from getting gloves caught in the spindle, socket or rotating part, as described in the Personal Protective Equipment Audit Performance Standard Modification of Portable Power and Machine Shop Tools Each site must develop and implement a process for the modification of Portable Power and Machine Shop Tools that meets the following minimum requirements: All modifications, from the original manufacturer s intended purpose, of portable power and machine shop tools must be approved by the original manufacturer or validated by a certified professional engineer (PE) or regional equivalent. Ensure that workers modifying portable power and hand tools are an authorized person Ensure that portable power and machine shop tools under modification are isolated where appropriate in accordance with the Hazardous/Lockout Energy Control Audit Performance Standard Ensure the portable power and machine shop tools are assessed, inspected and tested by a competent person prior to being returned to service Preventative Maintenance For all Critical Equipment identified in section of this standard, the site must establish a maintenance and inspection process that meets the following minimum requirements:

7 UAW-GM Safety System Audit Performance Standard Page 7 of 9 Portable power and machine shop tools must be maintained and inspected in accordance with the manufacturer or supplier recommendations and regulatory requirements (or as determined by a risk assessment) including all safety features and warning devices. Maintenance and inspections must be performed by a competent person. Follow the requirements outlined in in the Hazardous/Lockout Energy Control Audit Performance Standard when performing maintenance and inspections. A preventive maintenance system must be used to keep a record of maintenance for each item of portable power and machine shop tool. This includes scheduled maintenance, breakdown maintenance and replacement of parts outside the scheduled maintenance program Daily Pre-Operational Start Up Inspections The site must have a process in place to provide production workers with time, prior to the start of production, to perform a daily pre-operational start up inspection on portable power and machine shop tools (where required), based on the results of the hazard identification and risk assessment results as identified in section of this standard, GM requirements, regulatory requirements, or manufacturing inspection requirements. This inspection must be documented and any damaged, faulty or malfunctioning portable power and machine shop tool must be reported immediately to the worker s Group Leader or Supervisor for correction Training Each site must provide documented training in their SOP, standardized work, daily preoperational inspections, or maintenance work orders. The following are the minimum requirements to be included in the training: Selecting the right tool for the job. Knowing the hazards of the tool and its limitations. Using tools correctly (Safe Operating Procedures) Following safe operating procedures. Having guards in place (where fitted). Storing tools correctly. Selecting and using the correct Personal Protective Equipment (PPE) for the job. Hazardous/Lockout Energy Control procedures. How to report a portable power and machine shop tool related employee safe concern. What to do if a portable power and machine shop tools are damaged, faulty or present an immediate risk to health and safety. Training must be performed upon initial employment and/or job reassignment Documentation Documents and records related to portable power and machine shop tool activities must be included in the site s document control program as outlined in section 3.3 of UAW-GM Safety

8 UAW-GM Safety System Audit Performance Standard Page 8 of 9 System, and retained in accordance with ILM requirements. At a minimum, these include the following: Hazard Identification & risk assessment documentation. SOPs Daily pre-operational inspection records. Preventative Maintenance records Training records Management of Change The site is required to follow the requirements outlined in the Management of Change Audit Performance Standard UAW-GM APS , and must include portable power and machine shop tool risks associated with the following activities: Changes, modifications, or relocation of portable power and machine shop tools must go through the g-dhs process outlined in the g-dhs audit performance standard (UAW-GM SS APS ). Hazard identification and risk assessment documentation as outlined in section of this standard must be reviewed and updated as necessary. All new or transferred employees must receive portable power and machine shop tool training as outlined in section of this standard, as part of their new assignment. 5.0 Checking and Corrective Action Requirements 5.1 Planned Inspection The site must have a planned inspection process in place, as outlined in section of the UAW-GM Safety System. As part of this planned inspection program, sites must evaluate the following portable power and machine shop tools related items, at a minimum: Portable power and machine shop tool Safety Observation Tours: Portable power and machine shop tool SOTs in which the observers engage workers on their understanding of SOPs, identify process or systems failures, develop appropriate counter measures, and track to closure. Identification of damaged, faulty or malfunctioning portable power and machine shop tools. 5.2 Program Evaluation The site must perform an annual program review to evaluate implementation effectiveness. At a minimum, this review must include the following: Completion of Self-Assessment of this performance standard. Investigation reports of portable power and machine shop tool related incidents and sentinel events. Planned inspection records.

9 UAW-GM Safety System Audit Performance Standard Page 9 of 9 Related corrective and preventive actions to validate timely completion and evaluation of trends. Daily pre-operational inspections review. Training effectiveness. The results of this program evaluation must be reviewed during the Joint Leadership Review process as outlined in section 5.0 of the UAW-GM Safety System. 6.0 Related Documents Management of Change Global Design for Health & Safety (g-dhs) Ergonomics GM Global Ergonomics Specification for Machinery and Equipment. Revision Rev # Change Made Author(s) History Date Feb Initial Document based on GMS H&S Documents C.Kinnear & P.Harvey May 4, Revised to UAW-GM Language J Faulconbridge, A. Luna