Overview of machine hazards, and Machine Safeguarding with Lock Out Tag Out

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Machine SafeGuarding
with Lock Out
By Julian Kalac, P.Eng

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Scenario
Printing press
42 year old operator with 20 years exp.
Pinch point – 150psi
Distance from pinch point to safety stop
 8 feet
No guards in place
Operator goes to remove a paper
jam……..

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Result
Hospitalized for 1 week
Rehabilitation for 4-6 months
Severed tendons & nerves
Laceration to bone
Missing nerves & tendons
Loss of sensation
Loss of range or motion
Finger tips permanently bent
*These are only
The physical problems

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Any machine part,
function, or process
which may cause injury
must be safeguarded
Rule to Remember

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New Guards
for Printing Press

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Types of Hazardous
Mechanical Motions
and Actions
Rotating (including in-running nip points)
Reciprocating
Transverse
Cutting
Punching
Pinching
Shearing
Bending

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Rotating Motion
Common rotating mechanisms
 Collars
 Couplings
 Cams
 Clutches
 Flywheels
 Shaft ends
 Spindles
 Horizontal/vertical shafting

26. Dangerous moving parts in these basic areas require
safeguarding:
1. Point of operation
2. In running nip points
3. Pinch points
4. Power transmission
5. Other moving parts
Where Dangerous Mechanical Hazards Occur
Safeguarding can be accomplished by either machine guards or
machine devices.

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Types of Machine Guards
Guards
 Fixed
 Interlocked
 Adjustable
 Self-adjusting
Devices
 Presence sensing
 Photoelectrical (optical)
 Radio frequency (capacitance)
 Electromechanical

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Types of Machine Guards
Devices (cont’d)
 Pullback
 Restraint
 Safety controls
 Safety trip control
 Pressure-sensitive body bar
 Safety trip rod
 Safety tripwire cable
 Two-hand control
 Two-hand trip
 Gates
 Interlocked
 Other

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Fixed Guard
Provides a barrier - a permanent part of the
machine, preferable to all other types of guards.

30. Parts rotating in opposite direction
In-running nip point hazards
Rotating and tangentially
moving parts
Rotating Parts
Point of contact between a
chain and a sprocket

31. Examples of 3 Types of Motion
Rotating and fixed parts
Transverse motion
Rotating and tangential motion

32. Grinder Safety
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33. Grinder Safety (cont)
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34. Cutting Saws
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Point of contact Blade not guarded

35. Guarded vs Ungarded
Saw
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36. PINCH POINTS

37. LAMINATOR GUARDING
Interlocked Guarding
Mesh Guarding

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Adjustable Guard
Provides a barrier which may be adjusted to
facilitate a variety of production operations.
Bandsaw blade
adjustable guard

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Self-Adjusting Guard
Provides a barrier which moves according to
the size of the stock entering the danger area.
Circular table saw
self-adjusting guard

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Two-Hand Control
Requires constant,
concurrent pressure to
activate the machine
The operator’s hands
are required to be at a
safe location (on
control buttons) and at
a safe distance from
the danger area while
the machine completes
its closing cycle

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Gate
Movable barrier device which protects the operator at
the point of operation before the machine cycle can be
started
If the gate does not fully close, machine will not function
Gate Open Gate Closed

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Safeguarding by
Location/Distance
Locate the machine
or its dangerous
moving parts so that
they are not
accessible or do not
present a hazard to
a worker during
normal operation
Maintain a safe
distance from the
danger area

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Automatic Feed
(shown on power press)
Transparent
Enclosure
Guard
Stock Feed
Roll
Danger
Area
Completed Work

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Robots
Machines that load
and unload stock,
assemble parts,
transfer objects, or
perform other tasks
Best used in high-
production
processes requiring
repeated routines
where they prevent
other hazards to
employees

45. Example #1
Slitter guarding design using
mechanical guards

46. Front view of
mechanical guard

47. Example #1 SLITTER GUARDING USING
MECHANICAL GUARDS

48. Example #2
Slitter guarding design using light
curtains

49. Example #2
Slitter guarding using light curtains

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52. UNGUARDED

53. GUARDED

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Machine Safety
Responsibilities
Management
 ensure all machinery is properly guarded
Supervisors
 train employees on specific guard rules in their areas
 ensure machine guards remain in place and are functional
 immediately correct machine guard deficiencies
Employees
 do not remove guards unless machine is locked and
tagged
 report machine guard problems to supervisors
immediately
 do not operate equipment unless guards are in place

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Training Questions
How to use safeguards
Where are guards located
What hazards safeguards are
protecting against
When and how to remove guards
What to do if a guard is missing or
damaged

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Any machine part,
function, or process
which may cause injury
must be safeguarded
Rule to Remember

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QUESTIONS???

58. ADVANCED LOCK
OUT TAG OUT
ZERO ENERGY
By Julian Kalac, P.Eng
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Why Lock out tag out is
important?

60. LOCK OUT
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61. What is Lock Out Tag Out?
Lockout is defined in the Canadian standard
CSA Z460-05 (R2010) "Control of Hazardous
Energy”
Lockout is the isolation of energy from the
system (a machine/equipment/process) which
physically locks the system in a safe mode
Tag out is the labelling process always used
when lockout is required and includes the
following information:
 Time of application of the lock/tag.
 The name of the authorized person who
attached the tag and lock to the system.

62. Lock Out Tag Out Procedure
1. Prepare For Shutdown
Everyone in the area must be informed that Lockout/Tagout will be
performed and on which machines.
2. Identify Sources of Hazardous Energy on the
machine/equipment Assess equipment and identify the
hazardous energy sources (figure 1.0), either potential or
kinetic and determine the most effective method to achieve
a “ZERO ENERGY STATE”. Contact Manufacturing
Engineer (Julian Kalac) to help identify system shutdown
procedures.
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63. Examples of Types of
Hazardous Energy
Electrical
Hydraulic
Pneumatic
Mechanical potential energy
Gravitational potential energy –
Pressurized gasses
Chemical energy
other
Helping Our Customers Be More Successful . . .

64. General LOTO Procedure
STEP 1
ID Energy
Sources
STEP 2 Notify
Others
STEP 4
Isolate
Equipment
STEP 5
LOTO
Equipment
STEP 3
Shutdown
Equipment
STEP 6
Release
Stored
Energy
STEP 7 Verify
Isolation
STEP 8
Perform
Servicing
STEP 9
Release from
LOTO

65. Lock Out Tag Out
Procedure
3. Shutdown
Follow proprietary equipment and system shutdown procedures
normally used to stopping the equipment and return equipment
to a “ZERO ENERGY STATE” by methods described under
“General Lockout Guidelines” in Figure 1.0.
4. Apply Lock and Tag Information.
Locks Each worker will shall obtain his/her own individually
keyed lock. This is the workers own safety equipment is not to
be loaned. (No duplicate or master keys). When more than one
person use a multi-hinged hasp lockout device.
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6- Verify Effectiveness of Lockout
Ensure that all equipment energy sources are re-tested and a
“ZERO ENERGY STATE” has ben achieved. Use equipment
specified testing devices for system shutdown confirmation
such as Volt Meters, pressure gauges, blocks, bleeding devices
or cycling systems procedures.
7- Release From Lockout/Tagout
Before locks/tags are removed and energy is restored to the
machine/equipment, inspect the work area to ensure
components are operationally intact. Each lock and tag should
be removed from each energy- isolating device by the worker
who applied the lock and tag.
Lock Out Tag Out Procedure

67. SOURCES OF ENERGY
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ENERGY FORM ENERGY SOURCE GENERAL LOCKOUT GUIDELINE
Electricity
power transmission lines;
machine power
cords; motors;
solenoids;
capacitors
(stored
electrical
energy)
Turn off power at machine first (i.e., at point of
operation switch), and then at the main disconnect
switch for the machine; lock and tag main disconnect
switch (or remove fuses from box, and then lock and
tag box).
Fully discharge all capacitive systems (e.g., cycle machine
to drain power from capacitors) according to
manufacturer’s instructions.
Fluid pressure
hydraulic systems (e.g.,
hydraulic presses,
rams, cylinders,
hammers)
Shut off, lock (with chains, built-in lockout devices, o
lockout attachments) and tag valves; bleed off and
blank lines as necessary.
Air pressure
pneumaticsystems(e.g.,
lines, pressure
reservoirs,
accumulators, air surge
tanks, rams, cylinders)
Shut off, lock (with chains, built-in lockout devices, or
lockout attachments) and tag valves; bleed off excess
air; if pressure cannot be relieved, block any possible
movement of machinery.
Kinetic energy
blades;
flywheels
materials in supply lines
of bins or silos
Stop and block machine parts (e.g., stop flywheels
and
ensure that they do not recycle); review entire
cycle of mechanical motion, ensure that all
motions are stopped.
Block material from moving into area of work;
Potential energy
springs (e.g., in air brake
cylinders); actuators; counter
weights;
raised loads;
top or movable part of
a press or lifting device
If possible, lower all suspended parts and loads to
the lowers (rest) position, block parts that might be
moved by gravity; release or block spring energy.
Pressurized liquids
and gases
supply lines;
storage tanks and
vessels
Shut off, lock (with chains, built-in lockout devices,
or lockout attachments) and tag valves; bleed off
excess liquids or gases; blank lines as necessary.
Types of energy and how to LOTO

69. Never remove a lock, tag or block. Only
the person who placed it may remove it.
Never turn on or try to operate a machine
during lockout.
Stay clear of locked, tagged or blocked
machinery until you are notified the power
is back on
WARNING:

70. WARNING:
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