7.2: Activities Chapters 7,8,9,17,18 and 19-Industrial Safety - Manufacturing
- Page ID
- 18476
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\(\newcommand{\avec}{\mathbf a}\) \(\newcommand{\bvec}{\mathbf b}\) \(\newcommand{\cvec}{\mathbf c}\) \(\newcommand{\dvec}{\mathbf d}\) \(\newcommand{\dtil}{\widetilde{\mathbf d}}\) \(\newcommand{\evec}{\mathbf e}\) \(\newcommand{\fvec}{\mathbf f}\) \(\newcommand{\nvec}{\mathbf n}\) \(\newcommand{\pvec}{\mathbf p}\) \(\newcommand{\qvec}{\mathbf q}\) \(\newcommand{\svec}{\mathbf s}\) \(\newcommand{\tvec}{\mathbf t}\) \(\newcommand{\uvec}{\mathbf u}\) \(\newcommand{\vvec}{\mathbf v}\) \(\newcommand{\wvec}{\mathbf w}\) \(\newcommand{\xvec}{\mathbf x}\) \(\newcommand{\yvec}{\mathbf y}\) \(\newcommand{\zvec}{\mathbf z}\) \(\newcommand{\rvec}{\mathbf r}\) \(\newcommand{\mvec}{\mathbf m}\) \(\newcommand{\zerovec}{\mathbf 0}\) \(\newcommand{\onevec}{\mathbf 1}\) \(\newcommand{\real}{\mathbb R}\) \(\newcommand{\twovec}[2]{\left[\begin{array}{r}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\ctwovec}[2]{\left[\begin{array}{c}#1 \\ #2 \end{array}\right]}\) \(\newcommand{\threevec}[3]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\cthreevec}[3]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \end{array}\right]}\) \(\newcommand{\fourvec}[4]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\cfourvec}[4]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \end{array}\right]}\) \(\newcommand{\fivevec}[5]{\left[\begin{array}{r}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\cfivevec}[5]{\left[\begin{array}{c}#1 \\ #2 \\ #3 \\ #4 \\ #5 \\ \end{array}\right]}\) \(\newcommand{\mattwo}[4]{\left[\begin{array}{rr}#1 \amp #2 \\ #3 \amp #4 \\ \end{array}\right]}\) \(\newcommand{\laspan}[1]{\text{Span}\{#1\}}\) \(\newcommand{\bcal}{\cal B}\) \(\newcommand{\ccal}{\cal C}\) \(\newcommand{\scal}{\cal S}\) \(\newcommand{\wcal}{\cal W}\) \(\newcommand{\ecal}{\cal E}\) \(\newcommand{\coords}[2]{\left\{#1\right\}_{#2}}\) \(\newcommand{\gray}[1]{\color{gray}{#1}}\) \(\newcommand{\lgray}[1]{\color{lightgray}{#1}}\) \(\newcommand{\rank}{\operatorname{rank}}\) \(\newcommand{\row}{\text{Row}}\) \(\newcommand{\col}{\text{Col}}\) \(\renewcommand{\row}{\text{Row}}\) \(\newcommand{\nul}{\text{Nul}}\) \(\newcommand{\var}{\text{Var}}\) \(\newcommand{\corr}{\text{corr}}\) \(\newcommand{\len}[1]{\left|#1\right|}\) \(\newcommand{\bbar}{\overline{\bvec}}\) \(\newcommand{\bhat}{\widehat{\bvec}}\) \(\newcommand{\bperp}{\bvec^\perp}\) \(\newcommand{\xhat}{\widehat{\xvec}}\) \(\newcommand{\vhat}{\widehat{\vvec}}\) \(\newcommand{\uhat}{\widehat{\uvec}}\) \(\newcommand{\what}{\widehat{\wvec}}\) \(\newcommand{\Sighat}{\widehat{\Sigma}}\) \(\newcommand{\lt}{<}\) \(\newcommand{\gt}{>}\) \(\newcommand{\amp}{&}\) \(\definecolor{fillinmathshade}{gray}{0.9}\)Reflection: What tools and equipment do you use to do your work?
What are the primary energy sources? Describe one safety protocol and the hazard it addresses.
Flash Cards - Key Terms and Definitions
This interactive feature not available in print version of this workbook
Reflection:What tools, equipment, or machines have you operated that have guards?
Describe the primary method for guarding, i.e physical, sensing, interlock? View the video below and complete the following :
List the 5 Big Mistakes in Machine Guarding and refer to the seven common accident causes to associate one mistake with one cause. Share your thoughts on how the method of guarding impacts the potential for injury.
Video-Big 5 Mistakes
Flash Cards: Key Terms and Definitions
This interactive feature not available in print version of this workbook
Video Lockout/Tagout Safety, machine guarding
Name one big machine guarding mistake of the 5 shown in the video 5 big machine guarding mistakes that can be associated with not following lock out tag out procedures. Explain.
Video-Panduit-LOTO
Video-Big 5 Mistakes
Video-Machine Guarding
Video-Safe Work Manitoba
Video-Laser Guarding
No voice-No transcript
Case study - fatality
In your discussion groups view the amalgamation of video below and carefully note if the critical corrective actions are engineering or workplace controls. Discuss how electrical safety, LOTO, machine guarding, welding and confined spaces may often be considered together in a job hazard analysis.
Osha Cases on Electrical Safety, LOTO, Machine Guarding, Welding, and Confined Spaces
Video-Welder electrocuted
Video-LOTO
LOTO-Mechanical Systems
Video-Machine Guarding
Video-Confined Space Fire
Video-Milling Machines
General Lab Safety Procedures CNC Machines
Reflection: Recalling lab safety
The following is an excerpt from Wikipedia:
Numerical control (also computer numerical control, and commonly called CNC) is the automated control of machining tools (such as drills, lathes, mills and 3D printers) by means of a computer. A CNC machine processes a piece of material (metal, plastic, wood, ceramic, or composite) to meet specifications by following a coded programmed instruction and without a manual operator directly controlling the machining operation. Since any particular component might require the use of a number of different tools – drills, saws, etc. – modern machines often combine multiple tools into a single "cell". In other installations, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine.
View the series of videos on milling machines and identify three or more machine safety standards discussed in the safety protocols. How does understanding the safety standard help you understand machining or the process in general?
Video - Turning on a machine
Query \(\PageIndex{1}\)
Lab Safety Automation
Reflection - Industrial Safety and Automation
At the core of automation is programmable logic controls (PLCs) and smart logic (Robotics) machines designed to assist humans for efficient work. Most safety features are designed into the machines however those machines share working surfaces and spaces with people. Human-machine interface (HMI) has both ergonomic and physical safety components. View the video below on Amazon's Smart Warehouse and critique operations from your knowledge and understanding of Working and Walking Surfaces, and review of Machine and Robot Safety pages 8-11 (sections 2.1.1-2.1.5) What are good safety practices and what might be an accident waiting to happen? What safety standards seem to be in effect?
Video-Inside Amazon's Smart Warehouse
Video-How Amazon Drone Delivery Will Work
Reflection: Can you identify a confined space?
Review the examples of confined spaces and consider your present working environment. What similarities do you recognize? What are the physical conditions and what hazards might be present.
Flash Cards: Key Terms and Definitions
This interactive feature not available in print version of this workbook
Case study - Confined Space Fatality
In the follow case study several contributing factors to the fatallity were identified and many recommendations to prevent future occurrences. 3 of 5 contributing factors are listed below. In your discussion groups review the specifics of the case, noting your observations and then craft your own recommendations, minimum 6. After you are firm in your recommendations, view the actual recommendations from the case and see how many you duplicated.
- Work being performed inside of an energized machine that was not treated as a confined space
- Lockout/tagout (LOTO) procedures were not applied
- Failure to stop work despite an apparent machine malfunction.
Oregon Case Report: 17OR022
Release Date: June 2019
Summary
On July 12, 2017, a 49-year-old Certified Field Technician was killed after he climbed into a mechanical vertical storage unit to facilitate repairs. He had a new, inexperienced employee with him on the day of the incident; the Technician was training the new employee (Trainee) to perform routine preventive and/or scheduled maintenance (PM and/or SM). They completed one PM in the morning on a vertical storage machine. Work on a second machine was started after lunch at approximately 12:45 pm. A roller used to support a carrier tray fell out, and the Technician could not reinstall it from outside the machine. A carrier was removed to provide space for him to enter the unit. He climbed inside, to lie on a carrier below the removed one. As the trainee cycled the machine to put the Technician in a position to access and reinstall the roller, the machine malfunctioned. The Technician asked the trainee to make another input to the controls. The machine advanced the Technician over the top of the vertical storage unit, which had very limited space. This action crushed the Technician, leaving him on the sealed side, opposite the side where he started. Pry bars were used to extricate the Technician but resuscitation attempts failed.
Background
The two equipment technicians (one Certified, one a Trainee with no prior experience on this machine) arrived at the work site to perform preventive and/or scheduled maintenance (PM/SM) on two vertical storage units at a manufacturing facility. The units were owned by the host/contracting company and were used to maximize storage space while also enabling rapid retrieval of materials. In this type of machine, a series of numbered storage carriers are located on a vertical carousel, and a control panel is used to select the desired carrier number. The machine rotates in the most efficient direction and delivers the requested carrier to the opening. A light curtain is relied upon at the opening to stop operation if parts are sticking out, or if the operator breaks the opening space with any body parts. See the diagram on the next page for an example. The two workers had successfully performed a PM/SM on a different vertical storage unit that morning. That work was performed outside of the machine. After the lunch break, they went to the second unit, which was older than the first (built in 1998) but operated in a similar fashion and used for the same purpose. During maintenance, the experienced Certified Field Technician entered the machine by removing a carrier to make space for him to lie down on another carrier to investigate a “squeak.” The machine was energized, and the Trainee used the machine’s control panel to advance carrier numbers, thus moving the Technician inside of the machine. The Technician found excessive grease and was moved up and back to the opening twice without incident to clean the chain and related parts. Each time during this task the Trainee was able to move him up and back down by selecting the next carrier number; sequentially, and one at a time. This was done to ensure the machine moved as desired, and was thought to be the only way to ensure the employee did not move over the top or under the bottom of the unit to the other side. The potential for other types of movement in the machine with different control panel inputs was possible. The software used to rotate the carriers was designed to move to the selected one in the shortest distance to the opening. This typically doesn’t matter with storage material stored inside the carriers, but with the limited clearance and a worker inside of the machine, this feature was likely recognized as a critical hazard by the Certified Field Technician. In addition to the ability to move carriers with electrical power, the machine possessed a hand crank that could be used to rotate the carousel manually while the machine was de-energized. This alternative procedure would have allowed the unit to have been de-energized and LOTO procedures used. The employee could be moved as needed by the hand crank.
Reflection: Critiquing your working surface
Describe the type of surface you work on. What is the condition? Is it hard or soft surface? Indoors or outdoors? Elevated or below ground level. Which of the seven common accident causes is crucial for avoiding slips, trips, and falls on your working surface. Share the working and walking surfaces standard having the most impact at your place of employment or campus.
Flash Cards - Key Terms and Definitions
This interactive feature not available in print version of this workbook
Case study - Slips, trips, falls
A Stagehand Falls from the Ceiling of an Amphitheater-California FACE Report #12CA005
In your discussion groups review the fall fatality case above and identify as many of the seven common accident causes in the incident as you can. Be specific as you explain why.