Write a risk assessment for Machine safety

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# Compacting and baling equipment Compacting and baling equipment reduces large amounts of solid waste to smaller, more manageable units by means of powered rams. In general, compactors compress refuse into containers for transport. Baling equipment is designed to compress material (e.g., cardboard boxes) and produce a bale (bound or unbound) that is handled as a unit. A wide range of hazards exists simply due to the size, configuration, and operation of compactors and balers. Some machines allow direct access to the compression chamber, while others have a hopper or chute through which material feeds into the machine. Machines may operate in a manual, semiautomatic, or automatic mode. The rams may move vertically or horizontally. ## Hazard Workers can be crushed by the ram motion if guarding is missing or bypassed, or if lockout procedures are not followed during maintenance activities. Older compacting equipment may not have appropriate interlock guarding or may not have enough guarding to enclose the chamber or point-of-operation area completely. Severe injury and death can also occur during service or maintenance tasks on or inside an energized or jammed machine if the machine cycles automatically or if the machine is activated by another worker who is unaware that someone is inside the chamber. Because ram motion stops during a jam, workers may not recognize that the machine remains energized and that the ram could activate unexpectedly. Similarly, if conveyors are used to feed material into a compactor or baler, workers may mistakenly believe that shutting down the conveyor also prevents the compactor or baler from operating. In addition to the hazardous-energy potential, working inside these machines may also present confined-space hazards such as hazardous atmospheres and engulfment. ## Solution Access covers and point-of-operation guarding must be interlocked in such a manner that the compactor cannot be operated if the guard or loading door is remo…

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# The importance of machine safeguarding As long as workers need machines to help them process material - to cut, shear, punch, bend, or drill - they will be exposed to moving parts that could harm them. Much of the danger occurs at the point of operation, where the work is performed. ## Recent statistics that support the concern ## National Contact with objects and equipment (caught in, on, or under equipment or machinery only) • More than 690 fatalities per year • More than 137,600 lost workday injuries per year ● 1,400 amputations per year ## Oregon Contact with objects and equipment (caught in and struck by/against) - 13 compensable fatalities per year - 29 percent of all fatalities - 4,120 accepted disabling injuries ## About this guide This guide focuses on point-of-operation hazards and safeguarding methods and offers a comprehensive look at equipment and machinery commonly found in various Oregon workplaces. It does not specify all machine guarding requirements or all types of machinery or equipment. The reference section addresses typical hazards and guarding solutions related to power transmission devices, lockout/ tagout, and general safety principles for operating or maintaining machines and equipment. This guide also refers to many American National Standards. The American National Standards Institute (ANSI) publishes voluntary consensus standards on the care and use of machinery. ANSI standards provide guidance for complying with Oregon OSHA standards. ANSI standards are sometimes incorporated into Oregon OSHA regulations and employers are accountable for complying with the version specified. Oregon OSHA generally recommends, however, that employers follow the most recent ANSI standards. Of course, all original equipment manuals (OEMs) and other manufacturer suggestions must be strictly adhered to. In addition to ANSI, the International Organization for Standardization (ISO) standards provide requirements for personnel safety in the des…

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# Training guidelines An important step in machine safeguarding - a step often overlooked - is providing safety instruction and training on the various types of equipment the worker is expected to operate and the safeguarding the worker is expected to use. ## At a minimum, this education should include: - Discussion of hazardous exposures and control measures • Hazardous motions (rotating, reciprocating, and transverse) • Hazardous actions (cutting, bending, drilling, and punching, etc.) - Potential of flying or ejected material or parts • Effective safeguarding methods or other control measures (automatic/semi-automatic feeding/ ejection, guarding by location/distance, etc.) • Ergonomics (awkward posture, vibration, repetitive motion, forceful exertion, etc.) • Fire or combustion hazards (dust, lubricants, hot processes, hydraulic fluid, etc.) • Appropriate personal protective equipment and clothing - Health hazards - Air quality (dust, fumes or smoke from certain metals, mist from fluids, etc.) - Noise and vibration - Metalworking fluids (danger to skin, lungs, etc.) ## Equipment-specific training (hands-on) • Proper operation of safeguards ● Limitations • Maintenance and care ● Inspection ● Adjustment and placement - Clarification of manufacturer requirements • Procedures to follow when safeguard is discovered damaged, missing, etc. Training and relevant retraining must be provided for new operators and maintenance/setup employees. Also, retrain affected employees when new or altered safeguards are used, when an employee is assigned to a new machine or operation, and whenever worker deficiencies are discovered. Safeguarding strategies must include adequate management controls, such as accountability, enforcement, inspection, and maintenance. This can ensure clean and roomy work areas, properly maintained safeguards, and that lockout/tagout procedures are followed, to name a few. Finally, don't forget personal disabilities (e.g., c…

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# Risk reduction hierarchy A hierarchical approach is recommended when first approaching the safeguarding of a machine or operation. Safeguarding principles should be based on preventing access during dangerous motion or preventing dangerous motion during access. ## 1. Eliminate the hazard or exposure to the hazard • Design/redesign the operation to remove exposure (e.g., automatic feeding/ejection, designed enclosures) - Locate the hazard where it is not accessible due to its location or distance • Reduce energy - Replace/substitute ## 2. Prevent exposure • Fastened barrier guarding ● Metal or plastic enclosures • Fixed metal or plastic enclosures, guarding, screens, fence, etc. ● Adjustable guarding • Self-adjusting guarding • Interlocked, fixed barrier guarding (interlock or other inputs meeting safety-related performance levels) 3. Safeguard exposure • Devices that require adjustment or actuation by the user • Presence-sensing devices (e.g., light curtains, scanners, mats) • Gates - Two-hand controls and trips - Pullbacks and restraints • Safety-related control system meeting appropriate performance levels related to functional safety (ANSI B11.19; ISO [redacted postal code]; IEC [redacted postal code]) Remember, control inputs like presence-sensing devices and interlocks do not restrict or prevent access but only "sense" it. They rely entirely on their ability to both sense and switch (to instantly provide safety). It is imperative the control circuit meets appropriate performance levels related to functional safety. For many years, the term "control reliability" has been mainly defined by ANSI B11.19 addressing the safety performance of control circuits. However, the use of the term has declined in recent years due to the widespread acceptance of European Directives and International Standards such as ISO [redacted postal code] and IEC [redacted postal code]. These standards provide a more complete and verifiable means of spe…

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# Power roll forming and bending machine Conventional metal forming and bending machines, also known as plate bending rolls, produce smooth, circular bends in sheet, strip, or coiled stock. Metal is fed between successive pairs of rolls that progressively bend and form it until the desired shape and cross section is obtained. The radius of the bend can be adjusted by changing the location of the rolls. These machines are normally equipped with instant start, stop, and reverse controls. ## Hazard Severe crushing injuries, amputations, and even death can occur if a worker is caught and drawn into the counter-rotating infeed rolls. The risk of injury is high during the initial feeding of the stock. Wearing gloves with fingertips and loose clothing also increase the risk of entanglement. Workers can also be struck by the moving work piece or pinned between it and a fixed structure. ## Solution Installing fixed or adjustable barrier guarding at the point of operation is usually not practical, primarily due to the flexibility needed to bend various sizes of stock. Some protection for the operator and anyone near the machine can be provided by using devices such as safety trip cables (emergency stop) and hold-down controls; however, these safety devices do not directly prevent entanglement or entrapment. They are intended to help prevent or minimize injury by stopping the machine quickly. Hold-down button or foot controls are designed to actuate roll movement only when held in the run position. The control should automatically return to the stop position when released. A trip device (bar, tensioned wire/cable, or kick panel) is interlocked with the machine's control circuit and positioned so that it may be easily actuated by any person caught or drawn toward the rolls and will stop the machine before serious injury can occur. It should run the entire length of the machine at the front and in the back. Also, ensure the braking system is adequate, as the safety de…

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# Oregon OSHA standards related to machinery and machine guarding ## General Industry • Division 2/Subdivision I, Personal Protective Equipment • Division 2/Subdivision J, General Environmental Controls (Lockout/Tagout) • Division 2/Subdivision N, Material Handling and Storage • Division 2/Subdivision O, Machinery and Machine Guarding • Division 2/Subdivision P, Hand and Portable Powered Tools • Division 2/Subdivision R, Special Industries (sawmills, pulp and paper mills, etc.) • Oregon OSHA Program Directive A-280, National Emphasis Program on Amputations ## Construction ● Division 3/Subdivision E, Personal Protective and Life Saving Equipment ● Division 3/Subdivision I, Tools - Hand and Power ## Agriculture • Division 4/Subdivision I, Protective Equipment ● Division 4/Subdivision J, Work Environment (Lockout/Tagout) ● Division 4/Subdivision N, Material Handling • Division 4/Subdivision O, Equipment Guarding ● Division 4/Subdivision P, Small Tools - Forest Activities ● Division 7/Subdivision D, Personal Protective Equipment and Programs ● Division 7/Subdivision H, Machines Used in Forest Activities ## Oregon fatalities Operator pulled into a machine by a moving belt Worker caught in an irrigation spool Lathe operator hit by rotating bar stock Operator caught in keyed shaft (loose-fitting shirt contributed) Worker caught in a glue line conveyor 5 LO

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# Machine Guarding Inspection Checklist (cont.) <table><tr><th>13. Is sufficient clearance provided around and between machines to allow for safe operations, set up and servicing, material handling and waste removal?</th><th></th><th></th><th></th><th></th></tr><tr><td>14. Is equipment and machinery securely fastened to prevent tipping or other movement that could result in personal injury?</td><td></td><td></td><td></td><td></td></tr><tr><td>15. Is there a power shut-off switch within reach of the operator's position at each machine?</td><td></td><td></td><td></td><td></td></tr><tr><td>16. Can electricity and other forms of hazardous energy be locked out for maintenance, repair, or security?</td><td></td><td></td><td></td><td></td></tr><tr><td>17. Are the noncurrent-carrying metal parts of electrically operated machines bonded and grounded?</td><td></td><td></td><td></td><td></td></tr><tr><td>18. Are foot-operated switches guarded or arranged to prevent accidental actuation by personnel or falling objects?</td><td></td><td></td><td></td><td></td></tr><tr><td>19. Are manually operated valves and switches controlling the operation of equipment and machines clearly identified and readily accessible?</td><td></td><td></td><td></td><td></td></tr><tr><td>20. Are all emergency stop buttons colored red?</td><td></td><td></td><td></td><td></td></tr><tr><td>21. Are all belts/pulleys, chains/sprockets and other forms of power transmission that are within 7 feet of the floor or working level properly guarded?</td><td></td><td></td><td></td><td></td></tr><tr><td>22. Are protective safety guard measures provided to guard the operator and other employees in the machine area from hazards created at the point of operation, pinch points, and rotating parts?</td><td></td><td></td><td></td><td></td></tr><tr><td>23. Are precautions in place to prevent machines from automatically starting when power is restored after a power failure or shutdown?</td><td></td><td>ㅁㅁㅁ</td><td></td><td></…

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# Basic safety principles Although this guide addresses point-of-operation safeguarding for specific machinery, it is also important to establish and enforce safe work practices when operating and maintaining all types of equipment and machinery. The following list includes basic rules that apply to portable and fixed machinery: ## Equipment (parts include blades, bits, sanding belts, dies, grinding stones) ● Follow the equipment manufacturer's recommendations • Use equipment only for the purpose for which its design is intended • Operate the tool at the speed and tension specified by the manufacturer ● Inspect the equipment visually before use • Remove unadjusted, defective, cracked, or worn parts from service • Maintain sharp and clean parts • When provided, use equipment with an exhaust dust-collection system or • Use the appropriate size and type of part for the material and cutting action ● Check to see that guards, guides, and counterweights are properly adjusted and operable • Avoid overheating the equipment ## Work practices • Use only tools you can control easily • Make sure hands are kept at a safe distance • Follow safe procedures as outlined in the operator's manual • Always wear eye and face protection and other appropriate personal protective equipment • Do not wear loose clothing or long hair that may become entangled • Check to see that power cords are kept away from the line of cut and other moving parts • Follow proper lockout/tagout procedures during service and repair - Never defeat the guard to expose the blade • Never reach under the saw, work piece, or any place you can't see clearly - Direct the operation away from your body ## Work environment • Practice good housekeeping - avoid crowded, cluttered conditions • Make sure combustible or flammable material is located away from spark-producing operations • Provide adequate ventilation to reduce dust and other air contaminants • Monitor noise levels and provide hear…

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# Option 2 SAMPLE 2 Job Hazard Analysis for Personal Protective Equipment (PPE) Assessment Job/task: Lathe operator Location: Lathe room <table><tr><th>Job/Task Step</th><th>Hazard Type</th><th>Hazard Source</th><th>Body Parts At Risk</th><th>Severity</th><th>Probability</th><th>Risk Code</th><th>Control Method*</th></tr><tr><td>Pick up stock</td><td>Cuts</td><td>Sharp metal</td><td>hands</td><td>III</td><td>C</td><td>2</td><td>Leather gloves while handling</td></tr><tr><td></td><td>Sprain</td><td>Heavy metal</td><td>back</td><td>II</td><td>C</td><td>2</td><td>Hoist for heavy items</td></tr><tr><td></td><td>Crush</td><td>Heavy metal</td><td>feet</td><td>II</td><td>C</td><td>N</td><td>Steel Toed Shoes</td></tr><tr><td>Run Lathe</td><td>Impact</td><td>Revolving chuck</td><td>hands</td><td>II</td><td>C</td><td>N</td><td>Chuck guard</td></tr><tr><td></td><td>Impact</td><td>Metal Chips</td><td>face, eyes, hands</td><td>II</td><td>B</td><td>1</td><td>Safety Glasses, face shield, coveralls</td></tr><tr><td></td><td>Chemical</td><td>Coolant/Lube</td><td>hands</td><td>III</td><td>C</td><td>z N</td><td>Switch to non-irritating mixture</td></tr><tr><td></td><td>Repetitive Motion</td><td>Frequent control adjust</td><td>hands</td><td>II</td><td>D</td><td>3</td><td>Periodic rest breaks, vary task duties</td></tr><tr><td>Remove stock</td><td>(Same as</td><td>Pick up</td><td>stock)</td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td><…

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# Robots The industry standard, ANSI/RIA R15.06, defines an industrial robot as an automatically controlled, reprogrammable multipurpose manipulator, programmable in three or more axes, which can be either fixed in place or mobile for use in industrial automation applications. Furthermore, an industrial robot system comprises the robot (hardware and software) and consists of the control system, the end-effectors, and any associated machinery and equipment supporting the robot performing its task. An industrial robot system is usually not a stand-alone machine, but rather part of a larger system (or cell) interacting with other equipment. ## Hazard Although hazards associated with robots are well recognized, the actual hazard sources are often unique to a particular robot system and directly related to the nature of the automation process and the way it is installed, programmed, operated, and maintained. Hazards involving robots range from being struck by moving components and projectiles to trapping or crushing hazards, and dangers from inadvertent operation. Also, not recognizing risks from stored energy, faulty design or installation, and point-of-operation hazards from the end-effector add to the list. ## Solution Safeguarding robots and robot systems is normally accomplished through fixed barrier guards (fencing), interlocked movable barrier guards, presence sensing devices (e.g., light curtains, laser scanners, pressure- sensitive mats, and edges), and two-hand controls. A risk assessment should be conducted to best evaluate all of the hazards, most designed safeguards, and robot limits and functions. The risk assessment should identify each type of hazard and estimate the risk level based on frequency of exposure, and the probability and severity of injury. Emphasis should be placed on intended operations (e.g., teaching, verification, and maintenance), unexpected startup, access from all directions (space restrictions - operating, restricted, and saf…

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# CHAPTER 2 -- ENFORCEMENT POLICIES AND PROCEDURES (cont.) ## AND/OR (cont.) B. Minor Servicing Exception to the Lockout/Tagout Standard. Servicing and maintenance activities are permitted without machine or equipment LOTO pursuant to the minor servicing exception -- 1910.147(a)(2)(ii) note. Minor servicing activities, which take place during normal production operations and which are routine, repetitive, and integral to the use of machine/equipment for production, are not covered by the LOTO standard if alternative methods provide effective employee protection from hazards associated with the control of hazardous energy (e.g., unexpected start-up). Compliance with the machine guarding requirements of Subdivision O is an example of such alternative measures. Refer to Chapter 3, Section IV, for additional policy guidance. C. 1910, Subdivision O, Machinery and Machine Guarding. Machine guarding often becomes an integral and essential component of an overall energy control procedure and, many times, an important economical alternative to LOTO. An energy control procedure should be based upon a reliable hazard analysis that determines hazardous energy exposure so that hazards can be effectively controlled. This will provide effective employee protection during machine operation and component testing and positioning tasks, as well as during servicing and maintenance activities, and will help an employer comply with OR-OSHA's performance-oriented machine guarding and LOTO standards. - It is important to emphasize that the machine guarding requirements of Part 1910, Subdivision O standards complement the requirements for LOTO. In some instances, an employer may avoid the requirements of the LOTO standard, if he eliminates exposure to servicing and maintenance hazards by using machine guarding techniques compliant with those standards. - For example, the changing of dies on a full- or part-revolution mechanical power press requires the employer to establish a die-set…

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# Power-transmission apparatuses Power-transmission apparatuses include all components of the mechanical system that transmit energy to machines and equipment. Flywheels, couplings, pulleys, belts, cams, cranks, spindles, shafts, gears, chains, and sprockets are common examples of these components. ## Hazard Power-transmission apparatuses consist of parts that move to transmit energy, and provide a variety of hazards to operators and other workers, other than point of operation hazards. The most common hazard is the rotating motion from these components. Entanglement can occur from a single part (e.g., shaft) or parts rotating closely together, producing "in-running nip points." In- running nip points are caused when parts rotate against a fixed object (e.g., screw conveyor), parts rotate in the same direction (e.g., v-belt and pulley), or when their axes are parallel, but rotate in opposite directions (e.g., gears). Rotating collars, couplings, cams, clutches, flywheels, shaft ends, and spindles can grip clothing or otherwise force a body part into a dangerous location. Projections such as screws or burrs on the rotating part increase the likelihood of injury. Other components that move while the machine is operating, such as reciprocating and transverse moving parts, can create hazardous areas. Parts that move back-and-forth or up-and-down (reciprocating motion) can strike or entrap a worker between a moving part and a fixed object. Parts that move in a straight, continuous line (transverse motion) can strike or catch a worker in a pinch or shear point created by the moving part and a fixed object. ## Solution It is usually not difficult to guard these components. As a general rule, a power-transmission apparatus is best protected by fixed barrier guards that enclose the danger. Guards should be made of expanded metal, sheet or perforated metal, or other substantial material, and securely fastened to the frame of the machine, or the floor. Wood guards may b…

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# CNC turning machine Computer numerically controlled (CNC) machining centers cut and shape an assortment of precision products from automobile parts to general machine parts. Operating in either horizontal or vertical positions, CNC machinery includes machining tools such as lathes, multi-axis spindles, and milling and boring machines; the functions formerly performed by human operators are performed by a computer- control module. CNC machinery is either hand loaded or automatically fed. Most CNC machinery is partially or totally enclosed by metal enclosures equipped with thermoplastic vision panels, most commonly polycarbonate. ## Hazard Two primary hazards arise from CNC turning operations: entanglement and the ejection of parts. Serious lacerations, fractures, amputations, or even death can occur if an operator contacts or becomes entangled in or between the tooling or rotating work piece. Similar injuries or death can also occur from being struck by ejected parts (e.g., cutters or other tools, chucks, or the work piece). Although the risk of injury from ejected parts is lessened due to the interlocked enclosure of CNC machinery, recent research has shown that polycarbonate materials used in the unit's vision panels can degrade after exposure to the metalworking fluids and lubricants used in the machining process. Over time, vision panels may not be able to contain ejected parts. Most ejections at CNC turning machines are caused by a setup error or failing to properly maintain work-holding devices. Unexpected movement or startup caused by faults in the control system can also cause serious injury. ## Solution To prevent access into the point-of-operation area, ensure the CNC machine is fully enclosed and equipped with an interlocked guard (door). The cutting tools should not start unless the door is in a closed position and should stop when the door is opened. Many machines lock the guard in position during operation and can be opened only when the tool…

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# Option 2 # SAMPLE 1 Job Hazard Analysis for Personal Protective Equipment (PPE) Assessment Job/task: Mill Operator, Mill operator helper Location: Milling room <table><tr><th>Job/Task Step</th><th>Hazard Type</th><th>Hazard Source</th><th>Body Parts At Risk</th><th>Severity</th><th>Probability</th><th>Risk Code</th><th>Control Method*</th></tr><tr><td>Bridgeport Mill Operator</td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td>-Insert stock to chuck</td><td>penetration</td><td>moving cutter</td><td>fingers</td><td>I</td><td>с</td><td>1</td><td>Turn off cutter when changing stock</td></tr><tr><td>-Processing material</td><td>impact</td><td>flying metal chips</td><td>eyes, face</td><td>II</td><td>B</td><td>1</td><td>install clear guard and require safety glasses</td></tr><tr><td></td><td>penetration</td><td>moving cutter</td><td>fingers</td><td>I</td><td>с</td><td>1</td><td>install clear cutter guard</td></tr><tr><td></td><td>noise (86 dBA)</td><td>motor/cutter</td><td>ears</td><td>II</td><td>с</td><td>2</td><td>require ear plugs or muffs</td></tr><tr><td></td><td>chemical irritation</td><td>cutting fluid</td><td>hands</td><td>III</td><td>B A</td><td>z</td><td>switch to non-allergenic cutting fluid</td></tr><tr><td>- remove stock</td><td>penetration</td><td>metal shavings attached to stock</td><td>hands</td><td>III</td><td>с</td><td>3</td><td>be attentive to work</td></tr><tr><td>Mill Operator's Helper</td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td>- bring / take pallet of stock to from the milling machine</td><td>crush</td><td>rolling/falling stock</td><td>feet</td><td>II</td><td>с</td><td>2</td><td>require steel toe shoes</td></tr><tr><td></td><td>crush</td><td>rolling/falling stock</td><td>hands</td><td>III</td><td>B</td><td>z</td><td>wear leather gloves when handling stock by hand</td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></t…

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# Option 2 # Job Hazard Analysis for Personal Protective Equipment (PPE) Assessment Job/Task: Location: <table><tr><th>Job/Task Step</th><th>Hazard Type</th><th>Hazard Source</th><th>Body Parts At Risk</th><th>Severity</th><th>Probability</th><th>Risk Code</th><th>Control Method¹</th></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr><tr><td></td><td></td><td></td><td></td><td></td><td></td><td></td><td></td></tr></table> (1) Note: Engineering, work practice, and/or administrative hazard controls such as guarding must be used, if feasible, before requiring employees to use personal protective equipment. Certification of Assessment *Name of work place: <empty> *Address: <empty> *Assessment Conducted By: <empty> Title: <empty> *Date(s) of Assessment: <empty> Implementation of Controls Approved By: <empty> Title: <empty> Date: <empty> Page 24 24 24

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# Lockout/Tagout ## Safe work practices during service and repair Many serious injuries and fatalities occur when somebody mistakenly thinks a machine is safely isolated from its energy sources or stored energy has been relieved or blocked. Approximately 120 workers are killed in the U.S. every year from a failure to effectively isolate hazardous energy. Oregon OSHA's Hazardous Energy Control standard, commonly referred to as "lockout/tagout," covers the maintenance of machinery and equipment where unexpected startup, movement, or the release of stored energy can cause injury to workers. In general, the standard requires that all energy sources for machinery and equipment be turned off, isolated (disconnected), and physically locked out. Bleeding, relieving, or blocking other stored and residual energy must also be done to ensure isolation. The final important step before service begins is to verify all energy has been de-energized and isolated. These procedures, along with training and periodic audits, must be established and enforced. Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, are not covered by this standard if they are routine, repetitive, and integral to the use of the equipment for production, provided the work is performed using alternative measures that provide effective protection. Selection of an alternative control method must be based on a risk assessment of the machine, equipment, or process. The risk assessment must consider existing safeguards provided with the machine, equipment, or process that may need to be removed or modified to perform a given task. For example, when control circuits are used as part of the safeguarding system, the system must be designed to ensure protection as effective as a mechanical disconnect switch or master shutoff valve. A control- reliable dual-channel hardwired circuit of industrially rated components that satisfies the design fea…

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# Machine Guarding Safety Checklist (cont.) <table><tr><th>Protective Equipment &amp; Proper Clothing</th><th>Yes</th><th>No</th><th>N/A</th><th>Comments</th></tr><tr><td>32. Is protective equipment required?</td><td></td><td></td><td></td><td></td></tr><tr><td>33. If protective equipment is required, is it appropriate for the job, in good condition, kept clean and sanitary, and stored carefully when not in use?</td><td></td><td></td><td></td><td></td></tr><tr><td>34. Is the operator dressed safely for the job (i.e., no loose-fitting clothing or jewelry)?</td><td></td><td></td><td></td><td></td></tr><tr><td>Machinery Maintenance &amp; Repair</td><td>Yes</td><td>No</td><td>N/A</td><td>Comments</td></tr><tr><td>35. Have maintenance workers received up-to-date instruction on the machines they service?</td><td></td><td></td><td></td><td></td></tr><tr><td>36. Do formal LOTO procedures exist and do maintenance employees follow LOTO procedures when performing equipment maintenance?</td><td></td><td></td><td></td><td></td></tr><tr><td>37. Where several maintenance persons work on the same machine, are multiple lockout devices used?</td><td></td><td></td><td></td><td></td></tr><tr><td>38. Do maintenance persons use appropriate and safe equipment in their repair work?</td><td></td><td></td><td></td><td></td></tr><tr><td>39. Is the maintenance equipment itself properly guarded?</td><td></td><td></td><td></td><td></td></tr><tr><td>40. Do Authorized Maintenance Personnel receive formal LOTO training on an annual basis which covers OSHA requirements set forth in 29 CFR 1910.147 and machine specific LOTO procedures?</td><td></td><td></td><td></td><td></td></tr><tr><td>41. Do unauthorized personnel receive annual awareness level training which covers general machine safety, LOTO basics and instructions to Stop, Call and Wait for Authorized personnel to perform repairs when equipment malfunctions?</td><td></td><td></td><td></td><td></td></tr></table> KEMI does not assume liability…

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# Glossary of terms Adjustable barrier guard - A physical barrier requiring manual adjustment for various jobs. Brake monitor - A sensor designed, constructed, and arranged to monitor the effectiveness of the press braking system. Competent person - One who is capable of identifying existing and predictable hazards in the surroundings or working conditions that are unsanitary, hazardous, or dangerous to employees, and who has authorization to take prompt corrective measures to eliminate them. Control reliability (also called performance of safety-related functions) - A part of the system that controls hazardous motion of a machine. It ensures the machine will stop when required in the event of a single component failure within the system. Device - A control or attachment that: • Prevents a cycle if the operator's hands are inadvertently in the point of operation - Maintains the operator's hands at a safe distance during the hazardous portion of a cycle - Restrains the operator from inadvertently reaching into the point of operation • Automatically withdraws the operator's hands from the point of operation as the dies close Fixed (barrier) guard - A guard that provides a physical restriction to a hazard. Guard - A physical barrier that prevents entry of the operator's hands or fingers into the point of operation. A guard: • Must prevent any contact to the machine hazard and must be installed to prevent contact from around, over, through, or under the guard • Must not allow objects to fall into moving parts or be ejected toward a worker • Must not create a pinch point between it and moving machine parts • Must be affixed to the machine and remain secure • Must facilitate its own inspection and allow for maintenance and lubrication • Must offer maximum visibility of the point of operation consistent with the other requirements • Must conform to other appropriate standards (ANSI, manufacturer specifications, etc.) Interlocked guard - A barrier that, …