CAMANCHE Bevelers RISK ASSESSMENT Complete

SequenceNo.
Task Description Hazards
Severity
Exposure
Avoidance(Speed)BlindSpots)
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
1
LOTO Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean Weld step on machine
1
LOTO Cut by hydraulic leak S2 E1 A1 R2B 3
Design Component Covering
(Lexan or Steel)
1
LOTO
Hot surface-
motors/drives/hydraulic valves
S1 E2 A1 R3A 3
(Lexan or Steel)
1
LOTO Burns from hydraulic/lube oil S1 E1 A1 R4 3
(Lexan or Steel)
1 LOTO Electric Shock S2 E2 A2 R1 20 Proper procedures
1 LOTO Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
1
LOTO
Sharp edges or objects or
product
S2 E2 A2 R1 16 PPE, gloves, safety glasses
2
Change head (Spindle Head)
Crush hazard (Clamps, vee
blocks)
S2 E2 A2 R1 15 LOTO
2
Crush hazard (spindle, vee
blocks, clamps) installation
S2 E1 A2 R2B 20 Proper procedures
and 16 (PPE) Lift in proper
manner, wear gloves, boots etc.
2
Muscle strain from
weight/reach
2
Slip fall different level
(climbing on machine)
S2 E2 A2 R1 18 Anti slip surface, keep area clean Weld step on machine
2 Change head (Spindle Head) Stored energy spindle S2 E1 A2 R2B 15 LOTO
2
Stored energy hydraulics
(Spindle carriage, clamps,
walking beam table lift)
S2 E1 A1 R2B 15 LOTO
Add programming to place beams
in "park" position prior to LOTO,
provide indicator that beams are
in proper position.
2 Change head (Spindle Head) Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
2 Change head (Spindle Head) Hit by pipe S2 E2 A1 R2A 15 LOTO
2 Change head (Spindle Head) Stored energy spindle S2 E1 A2 R2B 15 LOTO
2
2
Change head (Spindle Head) Eye hazard - flying debris S2 E2 A2 R1 15 LOTO
and 16 (PPE) ,eye protection,
wear gloves, boots etc.
2
product
S2 E2 A2 R1 20 Proper procedures
15,16, 18, Remove pipe with
crane if tables can not be cleared
2 Change head (Spindle Head) Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
2 Change head (Spindle Head) Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
2 Change head (Spindle Head) Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses and 20
2 Change head (Spindle Head) Sharp Chips S2 E2 A2 R1 20 Proper procedures andd 21
2 Change head (Spindle Head) Pinch point cover S2 E2 A1 R2A 10 Design out pinch point add gas strut, dampener
3
Change Clamp
blocks)
S2 E2 A2 R1 15 LOTO Also No1 Interlock Barrier
3
Change Clamp
3
Change Clamp
Muscle strain from
weight/reach
S2 E1 A2 R2B 22 Create step on to machine
3
Change Clamp
S2 E2 A2 R1 22 Create step on to machine
3
Change Clamp Stored energy spindle S2 E1 A2 R2B 2
Safety Rate Control Circuit CAT
3, Cat 4
3
Change Clamp
also (2) Safety Rate Control
Circuit CAT 3, Cat 4
3 Change Clamp Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
3 Change Clamp Hit by pipe S2 E2 A1 R2A 15 LOTO 2
3 Change Clamp Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
3
Change Clamp
product
3 Change Clamp Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
3 Change Clamp Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
3 Change Clamp Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
3 Change Clamp Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
4
Change V Plate
blocks)
S2 E2 A2 R1 15 LOTO
4
Change V Plate
4
Change V Plate
Muscle strain from
weight/reach
S2 E1 A2 R2B 22 Create step on to machine
4
Change V Plate
4
Change V Plate Stored energy spindle S2 E1 A2 R2B 2
3, Cat 4
4
Change V Plate
4 Change V Plate Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
4 Change V Plate Hit by pipe S2 E2 A1 R2A 15 LOTO
4 Change V Plate Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
4
Change V Plate
product
4 Change V Plate Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
4 Change V Plate Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
4 Change V Plate Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
5
Change table height on walking beam Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
5
Change table height on walking beam Pinch point (pipe) S2 E2 A2 R1 15 LOTO
5
Change table height on walking beam Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
5
Change table height on walking beam Cut by hydraulic leak S2 E1 A1 R2B 3
(Lexan or Steel)
5
Change table height on walking beam Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
in proper position.
5
Change table height on walking beam Hit by pipe S2 E2 A1 R2A 15 LOTO
5
Change table height on walking beam Burns from hydraulic/lube oil S1 E1 A1 R4 3
(Lexan or Steel)
Prior to safeguard selection After safeguard Installation
Risk Assessment Documentation (Form 3)

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
5
Change table height on walking beam Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
6
Change tooling
blocks)
S2 E2 A2 R1 2
3, Cat 4
and 1
6
Change tooling
Crush hazard (pipe exit, fair
end)
S2 E2 A1 R2A 2
3, Cat 4
Stop fair ending when gate opens
Install gated area on upstreem
side.
6
Change tooling
S2 E1 A2 R2B 15 LOTO or 2 with controlled access
6
Change tooling Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean Add steps to access tooling
6
Change tooling
S2 E2 A2 R1 18 Anti slip surface, keep area clean Add steps to access tooling
6 Change tooling Pinch point (pipe) S2 E2 A2 R1 15 LOTO or 2 with controlled access
6 Change tooling Stored energy spindle S2 E1 A2 R2B 15 LOTO or 2 with controlled access
6
Change tooling
S2 E1 A1 R2B 15 LOTO or 2 with controlled access
6 Change tooling Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
6 Change tooling Hit by pipe S2 E2 A1 R2A 15 LOTO
6 Change tooling Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
6
Change tooling
product
S2 E2 A2 R1 15 LOTO and 16
6 Change tooling Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
6 Change tooling Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
6 Change tooling Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses and 21
6 Change tooling Sharp Chips S2 E2 A2 R1 21 Chip brush, clear chips and 16
6 Change tooling Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
7
Adjust tooling (shim at times)
blocks)
S2 E2 A2 R1 15 LOTO
7
end)
S2 E2 A1 R2A 15 LOTO 20
7
Adjust tooling (shim at times) Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
7
7 Adjust tooling (shim at times) Pinch point (pipe) S2 E2 A2 R1 15 LOTO
7
Adjust tooling (shim at times) Stored energy spindle S2 E1 A2 R2B 15 LOTO
7
7 Adjust tooling (shim at times) Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
7 Adjust tooling (shim at times) Hit by pipe S2 E2 A1 R2A 15 LOTO
7 Adjust tooling (shim at times) Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
7
product
7
Adjust tooling (shim at times) Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
in proper position.
7
Adjust tooling (shim at times) Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
7 Adjust tooling (shim at times) Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
7 Adjust tooling (shim at times) Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
7 Adjust tooling (shim at times) Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
8
Change gears ratio
Muscle strain from
weight/reach
8
Change gears ratio Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
8
Change gears ratio Stored energy spindle S2 E1 A2 R2B 15 LOTO
8
Change gears ratio
8 Change gears ratio Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
8
Change gears ratio
product
9
Adjust clamps (shim at times)
blocks)
S2 E2 A2 R1 15 LOTO
9
end)
S2 E2 A1 R2A 15 LOTO
9
Adjust clamps (shim at times) Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
9
9 Adjust clamps (shim at times) Pinch point (pipe) S2 E2 A2 R1 10 Design out pinch point
9
Adjust clamps (shim at times) Stored energy spindle S2 E1 A2 R2B 15 LOTO
9
9 Adjust clamps (shim at times) Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
9 Adjust clamps (shim at times) Hit by pipe S2 E2 A1 R2A 15 LOTO
9 Adjust clamps (shim at times) Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
9
product
9
Adjust clamps (shim at times) Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
9 Adjust clamps (shim at times) Entanglement spindle, gears S2 E2 A2 R1 15 LOTO 2
9 Adjust clamps (shim at times) Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
9 Adjust clamps (shim at times) Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
9 Adjust clamps (shim at times) Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
11
Adjust limit switches machine travel Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
11
Adjust limit switches machine travel
11 Adjust limit switches machine travel Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
11
Adjust limit switches machine travel
product

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
11 Adjust limit switches machine travel Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
13 Check height of table Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
14 Manually clamp Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
15 Cycle machine forward to bevel pipe Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
15
Cycle machine forward to bevel pipe
product
15
Cycle machine forward to bevel pipe Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
15 Cycle machine forward to bevel pipe Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
15 Cycle machine forward to bevel pipe Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
16
check bevel in machine
blocks)
S2 E2 A2 R1 15 LOTO add 1 Interlocking Barriers
16
end)
16 check bevel in machine Pinch point (pipe) S2 E2 A2 R1 15 LOTO
16
check bevel in machine Stored energy spindle S2 E1 A2 R2B 15 LOTO
16
16 check bevel in machine Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
16 check bevel in machine Hit by pipe S2 E2 A1 R2A 15 LOTO
16 check bevel in machine Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
16
product
16 check bevel in machine Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
16
check bevel in machine Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
16 check bevel in machine Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
16 check bevel in machine Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
16 check bevel in machine Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
16 #N/A #N/A #N/A #N/A #N/A
18
walk pipe out
end)
S2 E2 A1 R2A 1 Interlocked Barrier new tech?
18
walk pipe out Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
18 walk pipe out Pinch point (pipe) S2 E2 A2 R1 1 Interlocked Barrier
18 walk pipe out Pinch point (walking beam) S2 E2 A2 R1 1 Interlocked Barrier
18 walk pipe out Hit by pipe S2 E2 A1 R2A 1 Interlocked Barrier
18 walk pipe out Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
18
walk pipe out
product
18 walk pipe out Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
18 walk pipe out Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
20
Remove burr with file
end)
S2 E2 A1 R2A 1 Interlocked Barrier new tech?
20 Remove burr with file Pinch point (pipe) S2 E2 A2 R1 1 Interlocked Barrier
20 Remove burr with file Hit by pipe S2 E2 A1 R2A 1 Interlocked Barrier
20 Remove burr with file Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
20
Remove burr with file
product
20 Remove burr with file Cuts - sharp tools in motion S2 E2 A2 R1 16 PPE, gloves, safety glasses
20 Remove burr with file Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
20 Remove burr with file Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
20 Remove burr with file Puncture Wound File Tang S2 E2 A1 R2A 19 Proper tools
21
Remove chips with brush (possibly
long chips around pipe)
end)
S2 E2 A1 R2A 1 Interlocked Barrier
21
Pinch point (pipe) S2 E2 A2 R1 1 Interlocked Barrier
21
Hit by pipe S2 E2 A1 R2A 1 Interlocked Barrier
21
Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
21
product
21
Cuts - sharp tools in motion S2 E2 A2 R1 1 Interlocked Barrier
21
Entanglement spindle, gears S2 E2 A2 R1 1 Interlocked Barrier
21
Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
21
Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
22
Clean around floor (chips)
Muscle strain from
weight/reach
22
Clean around floor (chips) Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
22 Clean around floor (chips) Pinch point (pipe) S2 E2 A2 R1 10 Design out pinch point
22 Clean around floor (chips) Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
22
Clean around floor (chips) Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
in proper position.
22 Clean around floor (chips) Hit by pipe S2 E2 A1 R2A 15 LOTO
22 Clean around floor (chips) Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
22
Clean around floor (chips)
product
22
Clean around floor (chips) Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
22 Clean around floor (chips) Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
22 Clean around floor (chips) Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
24
Rotate spindle 120deg during setup
blocks)
S2 E2 A2 R1 15 LOTO
24
end)
24
Muscle strain from
weight/reach
S2 E1 A2 R2B 19 Proper tools control reliable jog switch
24
Rotate spindle 120deg during setup Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
24
24 Rotate spindle 120deg during setup Pinch point (pipe) S2 E2 A2 R1 15 LOTO

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
24
Rotate spindle 120deg during setup Stored energy spindle S2 E1 A2 R2B 15 LOTO
24
24 Rotate spindle 120deg during setup Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
24 Rotate spindle 120deg during setup Hit by pipe S2 E2 A1 R2A 15 LOTO
24 Rotate spindle 120deg during setup Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
24
product
24
Rotate spindle 120deg during setup Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
24
Rotate spindle 120deg during setup Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
24 Rotate spindle 120deg during setup Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
24 Rotate spindle 120deg during setup Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
24 Rotate spindle 120deg during setup Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
25
Remove chips from tool holders
blocks)
S2 E2 A2 R1 15 LOTO
25
end)
25
Remove chips from tool holders Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
25
25 Remove chips from tool holders Pinch point (pipe) S2 E2 A2 R1 15 LOTO
25
Remove chips from tool holders Stored energy spindle S2 E1 A2 R2B 15 LOTO
25
25 Remove chips from tool holders Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
25 Remove chips from tool holders Hit by pipe S2 E2 A1 R2A 15 LOTO
25 Remove chips from tool holders Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
25
product
25 Remove chips from tool holders Cuts - sharp tools in motion S2 E2 A2 R1 16 PPE, gloves, safety glasses
25
Remove chips from tool holders Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
25 Remove chips from tool holders Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
25 Remove chips from tool holders Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
25 Remove chips from tool holders Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
26
Remove chips from spindle
blocks)
S2 E2 A2 R1 15 LOTO
26
end)
26
Remove chips from spindle Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
26
26 Remove chips from spindle Pinch point (pipe) S2 E2 A2 R1 15 LOTO
26
Remove chips from spindle Stored energy spindle S2 E1 A2 R2B 15 LOTO
26
26 Remove chips from spindle Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
26 Remove chips from spindle Hit by pipe S2 E2 A1 R2A 15 LOTO
26 Remove chips from spindle Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
26
product
26
Remove chips from spindle Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
26
Remove chips from spindle Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
26 Remove chips from spindle Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
26 Remove chips from spindle Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
26 Remove chips from spindle Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
27 Paint bad bevels yellow Pinch point (pipe) S2 E2 A2 R1 1 Interlocked Barrier
27 Paint bad bevels yellow Hit by pipe S2 E2 A1 R2A 1 Interlocked Barrier
27 Paint bad bevels yellow Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
27
Paint bad bevels yellow
product
28
Drop in dump bay (manual operation
through control system)
Hit by pipe S2 E2 A1 R2A 20 Proper procedures
29
Roll/straighten crooked pipe
end)
29
Muscle strain from
weight/reach
S2 E1 A2 R2B 19 Proper tools
29
Roll/straighten crooked pipe Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
29 Roll/straighten crooked pipe Pinch point (pipe) S2 E2 A2 R1 1 Interlocked Barrier
29 Roll/straighten crooked pipe Hit by pipe S2 E2 A1 R2A 15 LOTO
29 Roll/straighten crooked pipe Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
29
product
29 Roll/straighten crooked pipe Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
29 Roll/straighten crooked pipe Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
30
Check land, bevel angle and ID
chamfer for burr
end)
S2 E2 A1 R2A 1 Interlocked Barrier
30
chamfer for burr
Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
30
chamfer for burr
Pinch point (pipe) S2 E2 A2 R1 1 Interlocked Barrier
30
chamfer for burr
Hit by pipe S2 E2 A1 R2A 1 Interlocked Barrier
30
chamfer for burr
30
chamfer for burr
product

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
30
chamfer for burr
30
chamfer for burr
31
View clamp pressure during setup Cut by hydraulic leak S2 E1 A1 R2B 3
(Lexan or Steel)
31
View clamp pressure during setup
Hot surface-
S1 E2 A1 R3A 16 PPE, gloves, safety glasses and (3) design Component Cover
31 View clamp pressure during setup Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
31 View clamp pressure during setup Pinch point rear of machine 0 0 0 20 Proper procedures
32
Unplug chip conveyor
blocks)
S2 E2 A2 R1 15 LOTO
32
end)
32
Muscle strain from
weight/reach
32
Unplug chip conveyor Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
32
32 Unplug chip conveyor Pinch point (pipe) S2 E2 A2 R1 20 Proper procedures
32
Unplug chip conveyor Stored energy spindle S2 E1 A2 R2B 15 LOTO
32
32 Unplug chip conveyor Hit by pipe S2 E2 A1 R2A 15 LOTO
32 Unplug chip conveyor Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
32
product
32 Unplug chip conveyor Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
32 Unplug chip conveyor Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
32 Unplug chip conveyor Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
32 Unplug chip conveyor Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
32 Unplug chip conveyor Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
32 Unplug chip conveyor Entanglement Chip Conveyor S2 E2 A1 R2A 19 Proper tools
33 Adjust RPM (spindle dial) Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
34 System startup (controls) Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
35
Lube pump replacement Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
36
Broken clamp bolt removal
blocks)
S2 E2 A2 R1 15 LOTO
36
end)
36
36
Broken clamp bolt removal Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
36
36 Broken clamp bolt removal Pinch point (pipe) S2 E2 A2 R1 15 LOTO
36
36 Broken clamp bolt removal Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
36 Broken clamp bolt removal Hit by pipe S2 E2 A1 R2A 15 LOTO
36 Broken clamp bolt removal Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
36
product
36
Broken clamp bolt removal Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
36
Broken clamp bolt removal Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
36 Broken clamp bolt removal Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
36 Broken clamp bolt removal Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
36 Broken clamp bolt removal Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
38
Walking beam coupling replacement
end)
38
Muscle strain from
weight/reach
38
Walking beam coupling replacement Pinch point (pipe) S2 E2 A2 R1 15 LOTO
38
Walking beam coupling replacement Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
38
Stored pneumatic energy
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
38
Walking beam coupling replacement Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
in proper position.
38
Walking beam coupling replacement Hit by pipe S2 E2 A1 R2A 15 LOTO
38
Hot surface-
38
Walking beam coupling replacement Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
38
Walking beam coupling replacement Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
40 Alignment roll drive reset Electric Shock S2 E2 A2 R1 15 LOTO
40 Alignment roll drive reset Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
41
Install/replace oil pads
end)
41
Muscle strain from
weight/reach
41
Install/replace oil pads Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
41 Install/replace oil pads Pinch point (pipe) S2 E2 A2 R1 15 LOTO
41 Install/replace oil pads Pinch point (walking beam) S2 E2 A2 R1 15 LOTO

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
41
Install/replace oil pads Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
in proper position.
41 Install/replace oil pads Hit by pipe S2 E2 A1 R2A 15 LOTO
41 Install/replace oil pads Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
41
product
41 Install/replace oil pads Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
41 Install/replace oil pads Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
41 Install/replace oil pads Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
42
Oil check/Add Oil/Way Lube System Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
42
Oil check/Add Oil/Way Lube System Pinch point rear of machine 0 0 0 15 LOTO
44
Oil change alignment rolls
end)
44
Muscle strain from
weight/reach
44 Oil change alignment rolls Pinch point (pipe) S2 E2 A2 R1 15 LOTO
44 Oil change alignment rolls Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
44
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
44
Oil change alignment rolls Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
in proper position.
44 Oil change alignment rolls Hit by pipe S2 E2 A1 R2A 15 LOTO
44
Hot surface-
S1 E2 A1 R3A 16 PPE, gloves, safety glasses
44 Oil change alignment rolls Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
44 Oil change alignment rolls Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
45
Oil change walking beam gear boxes
end)
45
Muscle strain from
weight/reach
45
Oil change walking beam gear boxes Pinch point (pipe) S2 E2 A2 R1 15 LOTO
45
Oil change walking beam gear boxes Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
45
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
45
Oil change walking beam gear boxes Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
in proper position.
45
Oil change walking beam gear boxes Hit by pipe S2 E2 A1 R2A 15 LOTO
45
Hot surface-
45
Oil change walking beam gear boxes Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
45
Oil change walking beam gear boxes Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
45 #N/A #N/A #N/A #N/A #N/A
46
Oil check walking beam gear boxes
end)
46
Muscle strain from
weight/reach
46 Oil check walking beam gear boxes Pinch point (pipe) S2 E2 A2 R1 15 LOTO
46 Oil check walking beam gear boxes Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
46
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
46 Oil check walking beam gear boxes Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
46 Oil check walking beam gear boxes Hit by pipe S2 E2 A1 R2A 15 LOTO
46
Hot surface-
46 Oil check walking beam gear boxes Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
46 Oil check walking beam gear boxes Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
46 #N/A #N/A #N/A #N/A #N/A
47
Lube material handling system
end)
47
Muscle strain from
weight/reach
47 Lube material handling system Pinch point (pipe) S2 E2 A2 R1 15 LOTO
47 Lube material handling system Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
47
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
47
Lube material handling system Free fall walking beam***** S2 E1 A2 R2B 15 LOTO
in proper position.
47 Lube material handling system Hit by pipe S2 E2 A1 R2A 15 LOTO
47
Hot surface-
47 Lube material handling system Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
47 Lube material handling system Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
47 #N/A #N/A #N/A #N/A #N/A
48
Pipe removal from reject bin
48
Muscle strain from
weight/reach
48
Pipe removal from reject bin Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
48 Pipe removal from reject bin Pinch point (pipe) S2 E2 A2 R1 20 Proper procedures

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
48
48
Pipe removal from reject bin Cut by hydraulic leak S2 E1 A1 R2B 3
(Lexan or Steel)
48 Pipe removal from reject bin Hit by pipe S2 E2 A1 R2A 1 Interlocked Barrier
48 Pipe removal from reject bin Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
48
product
48 Pipe removal from reject bin Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
49
Accumulator replacement
Muscle strain from
weight/reach
49
Accumulator replacement Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
49
49 Accumulator replacement Cut by hydraulic leak S2 E1 A1 R2B 15 LOTO
49
Hot surface-
49 Accumulator replacement Burns from hydraulic/lube oil S1 E1 A1 R4 16 PPE, gloves, safety glasses
49 Accumulator replacement Electric Shock S2 E2 A2 R1 20 Proper procedures
49 Accumulator replacement Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
49 Accumulator replacement Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
49 #N/A #N/A #N/A #N/A #N/A
50
Hydro valve replacement
Muscle strain from
weight/reach
50
Hydro valve replacement Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
50
50 Hydro valve replacement Cut by hydraulic leak S2 E1 A1 R2B 15 LOTO
50
Hot surface-
50 Hydro valve replacement Burns from hydraulic/lube oil S1 E1 A1 R4 16 PPE, gloves, safety glasses
50 Hydro valve replacement Electric Shock S2 E2 A2 R1 15 LOTO
50 Hydro valve replacement Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
50 Hydro valve replacement Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
51
Heat exchanger
Muscle strain from
weight/reach
51
Heat exchanger Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
51
Heat exchanger
51 Heat exchanger Cut by hydraulic leak S2 E1 A1 R2B 15 LOTO
51
Heat exchanger
Hot surface-
51 Heat exchanger Burns from hydraulic/lube oil S1 E1 A1 R4 16 PPE, gloves, safety glasses
51 Heat exchanger Electric Shock S2 E2 A2 R1 15 LOTO
51 Heat exchanger Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
51 Heat exchanger Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
52
Pump replacement hydro
Muscle strain from
weight/reach
52
Pump replacement hydro Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
52
52 Pump replacement hydro Cut by hydraulic leak S2 E1 A1 R2B 15 LOTO
52
Hot surface-
52 Pump replacement hydro Burns from hydraulic/lube oil S1 E1 A1 R4 16 PPE, gloves, safety glasses
52 Pump replacement hydro Electric Shock S2 E2 A2 R1 15 LOTO
52 Pump replacement hydro Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
52 Pump replacement hydro Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
54
General maintenance
blocks)
S2 E2 A2 R1 15 LOTO
54
General maintenance
end)
54
General maintenance
54
General maintenance
Muscle strain from
weight/reach
S2 E1 A2 R2B 20 Proper procedures 19
54
General maintenance Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
54
General maintenance
54 General maintenance Pinch point (pipe) S2 E2 A2 R1 15 LOTO
54 General maintenance Pinch point (walking beam) S2 E2 A2 R1 20 Proper procedures
54 General maintenance Stored energy spindle S2 E1 A2 R2B 15 LOTO
54
General maintenance
54 General maintenance Cut by hydraulic leak S2 E1 A1 R2B 15 LOTO
54 General maintenance Hot tooling S1 E2 A2 R2C 15 LOTO
54
General maintenance
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
54
General maintenance Free fall walking beam***** S2 E1 A2 R2B 20 Proper procedures
in proper position.
54 General maintenance Hit by pipe S2 E2 A1 R2A 15 LOTO
54
General maintenance
Hot surface-

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
54 General maintenance Burns from hydraulic/lube oil S1 E1 A1 R4 16 PPE, gloves, safety glasses
54 General maintenance Electric Shock S2 E2 A2 R1 15 LOTO
54 General maintenance Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
54
General maintenance
product
54 General maintenance Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
54 General maintenance Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
54 General maintenance Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
54 General maintenance Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
54 General maintenance Pinch point rear of machine 0 0 0 15 LOTO
54 General maintenance Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
54 General maintenance Puncture Wound File Tang S2 E2 A1 R2A 19 Proper tools
54 General maintenance Entanglement Chip Conveyor S2 E2 A1 R2A 16 PPE, gloves, safety glasses
54 General maintenance Arc Flash S2 E1 A2 R2B 15 LOTO
56
Recover pipe that has fallen through
walking beam
blocks)
S2 E2 A2 R1 15 LOTO
56
walking beam
end)
56
walking beam
56
walking beam
Muscle strain from
weight/reach
56
walking beam
Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
56
walking beam
56
walking beam
Pinch point (pipe) S2 E2 A2 R1 15 LOTO
56
walking beam
Pinch point (walking beam) S2 E2 A2 R1 15 LOTO
56
walking beam
Stored energy spindle S2 E1 A2 R2B 15 LOTO
56
walking beam
56
walking beam
Cut by hydraulic leak S2 E1 A1 R2B 3
(Lexan or Steel)
56
walking beam
Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
56
walking beam
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
56
walking beam
Free fall walking beam***** S2 E1 A2 R2B 20 Proper procedures
in proper position.
56
walking beam
Hit by pipe S2 E2 A1 R2A 15 LOTO
56
walking beam
Hot surface-
56
walking beam
Burns from hydraulic/lube oil S1 E1 A1 R4 16 PPE, gloves, safety glasses
56
walking beam
Electric Shock S2 E2 A2 R1 15 LOTO
56
walking beam
56
walking beam
product
56
walking beam
Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
56
walking beam
Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
56
walking beam
56
walking beam
56
walking beam
Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
56
walking beam
Entanglement Chip Conveyor S2 E2 A1 R2A 15 LOTO
57
Change/Adjust sensors
blocks)
S2 E2 A2 R1 15 LOTO
57
end)
57
57
Muscle strain from
weight/reach
57
Change/Adjust sensors Slip fall same surface S2 E2 A1 R2A 18 Anti slip surface, keep area clean
57
57 Change/Adjust sensors Pinch point (pipe) S2 E2 A2 R1 15 LOTO
57 Change/Adjust sensors Pinch point (walking beam) S2 E2 A2 R1 20 Proper procedures
57 Change/Adjust sensors Stored energy spindle S2 E1 A2 R2B 15 LOTO
57
57
Change/Adjust sensors Cut by hydraulic leak S2 E1 A1 R2B 3
(Lexan or Steel)
57 Change/Adjust sensors Hot tooling S1 E2 A2 R2C 16 PPE, gloves, safety glasses
57
(clutch, clamps)
S1 E1 A1 R4 15 LOTO
57
Change/Adjust sensors Free fall walking beam***** S2 E1 A2 R2B 20 Proper procedures
in proper position.
57 Change/Adjust sensors Hit by pipe S2 E2 A1 R2A 15 LOTO
57
Hot surface-

SequenceNo.
Severity
Exposure
(Environment)
RiskCategory
Solution#
Solutions
Exposure
(Environment)
Severity
RiskCategory
57 Change/Adjust sensors Burns from hydraulic/lube oil S1 E1 A1 R4 16 PPE, gloves, safety glasses
57 Change/Adjust sensors Electric Shock S2 E2 A2 R1 15 LOTO
57 Change/Adjust sensors Eye hazard - flying debris S2 E2 A2 R1 16 PPE, gloves, safety glasses
57
product
57 Change/Adjust sensors Cuts - sharp tools in motion S2 E2 A2 R1 15 LOTO
57 Change/Adjust sensors Entanglement spindle, gears S2 E2 A2 R1 15 LOTO
57 Change/Adjust sensors Burns from chips S1 E2 A2 R2C 16 PPE, gloves, safety glasses
57 Change/Adjust sensors Sharp Chips S2 E2 A2 R1 16 PPE, gloves, safety glasses
57 Change/Adjust sensors Pinch point rear of machine 0 0 0 15 LOTO
57 Change/Adjust sensors Pinch point cover S2 E2 A1 R2A 10 Design out pinch point
57 Change/Adjust sensors Entanglement Chip Conveyor S2 E2 A1 R2A 19 Proper tools

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