The decision to purchase new machinery for your production line is no easy task. New equipment can bring increased productivity as well as transition challenges. Costs can rise profoundly when safety isn’t factored into the purchase and implementation of new equipment.
When considering a new equipment purchase, a business owner or operator often considers the following: productivity, labor requirements, space savings, power efficiency, warranty, purchase price and more. Unfortunately, safety and ease of operation may be ignored.
Through the years, this column has explored key forms that can be used when installing new machinery. These forms include: The Job Hazard Analysis, and The Job Task, Equipment, Process, & Engineering Control Change Assessment forms. Simple assessments can go a long way to identify and mitigate any hazards associated with new equipment.
This form is designed to be utilized prior to machinery changes or purchasing new equipment.
The following is a list from the form:
Description of Change: _________________________
First, let’s look at the reason for the change. The Job Task, Equipment, Process, & Engineering Control Change Assessment identifies the following as reasons for the change:
o Employee safety
o Hazard exposure elimination or reduction
o Production improvements
o Cost factors
o Environmental
o Building changes or additions
o Equipment changes
o Incident trend
o Regulatory compliance
Once the reason for the change has been determined, then decide whether the change is permanent, or temporary. The duration plays a large role in determining the task, process, or whether the equipment will need to be purchased, possibly leased, or even having the task outsourced. This is an important factor in the initial setup, safety
program requirements, and what must be done to comply with OSHA requirements. This includes: training, energy sources, placement and equipment securement, permanent barriers, guarding, and administrative and engineering controls.
Change Duration:
o Permanent o Temporary
Then identify the hazardous exposures related to the equipment, process, or job task:
Hazardous Conditions, Areas, or Points to Consider:
o Pinch Points
o Catch Points
o Blades
o Shafts / Belts / Gears
o Flash / Ultraviolent
o Hot Surfaces
o Severe Temperatures
o Traffic
o Pedestrians
o Elevated Height
o Bio-Hazards
o Airborne Particles
o Chemical Hazards
o Heavy Lifting
o Repetitive Motion
o Work Surfaces
o Confined Space
o Electrical
o Suspended Load
o Noise / Decibel Level
As an example, I recently visited a manufacturing plant that purchased a new piece of equipment. After putting it into service, the client wanted a safety review to analyze hazardous exposures and point of operation guarding. I requested that the safety committee join the analysis process along with the operations manager and equipment operator.
The manufacturer had made great steps in reducing the hazardous exposures related to the equipment. Noise levels were below 70 db, and the equipment had various built-in exposure controls, such as a pressure sensitive barrier that stopped the in-feed immediately when a person would make contact. This helped prevent entanglement or the worker from being pulled into the points of operation. All power driven parts were fully guarded, leaving no catch points or pinch points. The equipment was also equipped with auto shutdown, if any side panels were opened. The operational and energy controls could easily be isolated and locked out, since the main control was equipped with a position for a lock and tag.
We started our inspection of the equipment, and as mentioned, the equipment was already in-service. In emergency management training you were always taught to size-up the situation from a distance, and I still use that training today. When looking at the equipment, the first thing I noticed was the proximity to the forklift lane.
In looking at the Hazardous Conditions, Areas, or Points to Consider on our form, there were only three hazardous exposures needing addressed.
Hazard Exposure
Traffic Forklift lane
Airborne Particles Exposure from other tasks or equipment in vicinity
Noise / Decibel Level Exposure from other tasks or equipment in vicinity
Traffic—Forklift lane
Due to the space or equipment’s footprint, the setup location for this busy production plant didn’t have a lot of options. The location needed to be in the right order of the process, and once set-up, there would be no moving it.
The equipment was designed for a single operator. The location of the equipment, in proximity to a wall on one side, would require the operator to feed the material on one end, and then walk around to the other end to the out-feed. This was a distance of less than 12 feet. Each time the operator would walk around the machine, the employee was exposed to forklift traffic. Since we couldn’t move the location, we would have to make other changes to ensure the safety of the operator.
With every consideration of equipment or task changes for the purpose of employee safety, we need a process, and for this we use the Hierarchy of Controls. In this process, you always want to start from the top of this inverted pyramid and work down. The further down the controls you go, the least effective the control.
We will use the Hierarchy of Controls to assist us in eliminating the forklift exposure.
o Elimination of the process to remove the hazard was not an option, since the equipment had already been purchased, installed, and placed into service.
o Substitution or replacing the hazard was not an option.
o Engineering Controls: Isolation of people from the hazard was our best option.
A barricade was installed to keep forklifts 24" further from the equipment. This provided walking space for the equipment operator. In order to make the 24" adjustment, the forklift lane would have to be moved 24" toward the opposite side of the lane. Material storage and pallet racks were moved 24" over to allow the forklift lane repositioning.
o Administrative Controls would be put into place through making a slight change in the forklift lane. Policies were put into place to ensure forklift operators understood the importance of the barrier, and the plant speed of three miles per hour was reinforced.
o Personal Protective Equipment
Airborne Particles — Exposure
We will use the Hierarchy of Controls to assist us in eliminating the airborne particle exposure.
o Elimination: The hazard cannot be fully eliminated due to the use of hand operated power tools in various areas of the plant. Employees may walk in closer proximity to power tools while performing their tasks.
o Substitution or replacing the hazard was not an option.
o Engineering Controls: Put into place through work station placement that reduced the exposures to other workers.
o Administrative Controls: Policies were put into place to require all personnel to wear safety glasses while in production, and those operating the power tools to wear safety glasses and face shields.
o Personal Protective Equipment: Approved safety glasses were provided for the entire staff.
Noise / Decibel Level — Exposures Above 80 db
We will use the Hierarchy of Controls to assist us in eliminating the noise particle exposure.
o Elimination: The hazard cannot be fully eliminated due to the use of hand operated power tools in various areas of the plant. Employees may walk in closer proximity to power tools while performing tasks.
o Substitution or replacing the hazard was not an option.
o Engineering Controls: All other equipment has been insulated to reduce noise exposures.
o Administrative Controls: Policies were put into place to require all personnel to wear approved hearing protection while in production.
o Personal Protective Equipment: Approved hearing protection was provided for the entire staff
It’s obviously best to utilize The Job Task, Equipment, Process, & Engineering Control Change Assessment prior to the equipment being purchased. In this sequence decisions can be made that may save money. Once the equipment has been put into service, options are reduced, and it becomes more difficult to make decisions and changes. Engineering control changes can be much easier and less expensive when considered prior to buying the equipment.
Training is a critical part of new tasks, processes, and equipment safety. The Job Task, Equipment, Process, & Engineering Control Change Assessment can easily be made into a training document to review with employees. Utilizing the exposures already identified on the form, you can then review them with employees. As with any safety initiative, communication is the key.
Editor’s Note: Jary Winstead is a safety consultant, author and trainer who serves a variety of industries including the forest products sector. He owns Work Safety Services LLC and can be reached at SAFEJARY@gmail.com.
