lockout/tagout – alternative methods (risk assessment) w. jon wallace, csp, mba workplace group o:...
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Lockout/Tagout – Alternative Methods (Risk Assessment)
W. Jon Wallace, CSP, MBAWorkplace GroupO: 919.933.5548E: [email protected]
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Compressed Springs
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Is this an energy isolating device?
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Human Safety Blocks?
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Equipment-Specific Lockout Procedures: 1910.147(c)(4)
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What about tasks you perform routinely where the equipment must remain energized?
Alternative Methods – Risk Assessment
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A word about risk
Risk: Severity X Frequency X Probability
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Plastic Injection Molding Machine
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Industrial Robot
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Example of equipment-retrofit:
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References for performing Risk Assessment:
• ANSI Z244.1: Control of Hazardous Energy - Lockout/Tagout and Alternative Methods.
• ANSI/RIA R15.06: Industrial Robots and Robot Systems - Safety Requirements.
• ANSI B11.19: 2010 Performance Requirements for Safeguarding
• OSHA CPL: 02-00-147: The Control of Hazardous Energy – Enforcement Policy and Inspection Procedures
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Performing Risk Assessment:
1. Identify all tasks: Tasks where equipment must remain energized.
2. Identify Hazards: Electrical; gravity; chemical; pneumatic; etc.
3. Assess Potential Consequences: Worst case scenario (injury).
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Performing Risk Assessment (Cont’d):
4. Assess potential exposure to hazards.
5. Assess probability of occurrence.
6. Evaluate the risk.
7. Achieve an acceptable level of risk.
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Let’s Perform an Example:
• Employee changes tooling on robot once per shift. Existing interlock category: R2C
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A Word about interlocks (per ANSI/RIA R15.06) :
Category Circuit Performance
R1 Control Reliable
R2A Control Reliable
R2B Single Channel with monitoring
R2C Single Channel
R3A Single Channel
R3B Simple (Simple safety circuit)
R4 Simple (Simple safety circuit)
How to determine interlock: Manufacturer and E&I folks.
Increasing Sophistication
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Back to our example:
Employee changes tooling on robot once per shift. Existing interlock category: R2C
Task Hazard(s) Severity Exposure (Frequency)
Avoidance Protective Measures
Risk Reduction Required
Changing tooling on robot.
Struck by (moving robot).
S2 (Serious injury)
E1 (Infrequent)
A2 (Not likely to move out of way)
Interlock: R2C
R2B
LEGEND:
Summary: Interlock needs to be upgraded from R2C to R2B.
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Interlock requirement (ANSI/RIA R15.06)
Remember: S2; E1; A2.
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Putting it all together:
• Evaluate your lockout/tagout program.• Implement upgrades as needed.• Inventory tasks where equipment must
remain energized.• Perform risk assessment using ANSI
Lockout and Robotic standards.• Upgrade safeguards as needed.
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Conclusion
Question/Comments?