just a ppt in progress

1. Background
• Classes: OSHA 10/30 Hour, Incident Investigation, Confined
Space, Excavation Safety, Cranes Signaling, Rigging Safety,
Fall Protection, Scaffold Competent Person, Silica
Competent Person, CHST Prep, Lockout, Machine Guarding,
OSHA Recordkeeping, and Safety Management
• Services: Mock OSHA Inspections, Site Safety Audits, Expert
Witness,
• Since 1987, he has trained over 50,000 people including
OSHA compliance officers and Fortune 500 Clients in
numerous areas of Safety and Health.
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40 years working with top companies to
achieve world class safety in their sector.
815-354-6853 johnanewquist@gmail.com

2. Bacardi

3. John Newquist, MS, CSP, CHST
Draft 10 10 2017

4. Top Safety Results
Lost days went from 400 to 38 to 5.

5. 5

6. Jan 2018

7. Dupont

8. 2017

10. Mar 2018
• What design change would you
make?

11. Mar 2018

12. Spark Detection
$2800
Kingston NY
(c) Main plant and vat room. On or prior to 5/7/15, ductwork was not
equipped with a spark detection and extinguishing system installed between
the last collection point and the dust collector unit. The system was used to
collect wood dust from processes using recycled wood and tramp metal
fragments were present in the dust stream. Ignition sources included static
electricity and tramp metal

13. Design
Issues?

14. Design
Issues?

15. Design
Issues?

16. Consequence

17. Data
• 35% of all fatalities occurred in
workers age 55 or older, with
1,691 deaths.
• This is the highest number of
fatalities ever recorded for this
group of workers.

18. June 2016
• Columbus WI
• The teen was working at the factory
on June 27, 2016 when he was pinned
in a machine while cleaning scrap
from underneath a laser cutter in
operation.
• He later died of his injuries on July 2,
2016.
• The teen had only been working there
two weeks when the incident
happened.
This IS my sister-in-law's nephew !!!
Killed at 17 ... all because of company
not following safety rules, providing
proper training and equipment to
ensure lockout/tagout - DA

19. ANSI B Series
The user shall designate, provide, and ensure
the use of at least one of the following methods
of safeguarding that affords protection for the
operator, consistent with the requirements of
the task:
• guard(s)
• safeguarding device(s)
• awareness barrier(s) or awareness device(s)
• safe work procedure(s).
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20. June 2014
• Jake Frisella, a 21-year-old
machine operator, was fatally
crushed reaching into an auto
bumper machine to align parts
on June 10, 2014.
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Typical Auto bumper assembly machine

21. Machine Guarding

22. August 2016
22

23. July 2014
• Henderson NV Police and Fire
Department officials responded
at about 10:30 a.m. Saturday to
reports that a man had fallen
through a skylight at the Ocean
Spray facility
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He was my dad, thank you everybody, I am McKenzie Lane Lentz, 16.
Harry's youngest daughter . I hold them 1OO% responsible . I miss him
with all my heart . I can never see his face again . He was my everything .

24. Skylights
• Skylights need to be covered
with a barrier if employees
are allowed onto the roof.
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25. Parapet Fall Protection
• Several types are available.
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26. Roof Hatch
• Propped open is a fall hazard
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27. Costs of Accidents
• Work injury costs:
• Total cost in 2016.................................................... $241.5 billion
• Cost per death...........................................................$1,000,000
• Cost per medically consulted injury................................ $31,000
• The average cost for all worker comp claims combined in 2013-2014 was $38,617
• The average cost for all worker comp claims falls or slips ($45,016)
• Time Lost Due to Work-Related Injuries:
• Total time lost in 2016............................................... 100,000,000 days
• Due to injuries in 2016.................................................. 65,000,000 days
• Due to injuries in prior years.......................................... 35,000,000 days
• Time lost in future years from 2016 injuries....................... 50,000,000 days
• * Above data taken from NSC Injury Facts 2017 Edition.
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28. Worker Comp 2016
• Per Liberty Mutual Research Institute March 2016
• Worker comp at 16 year low.
• Falls on same level $10.6 billion 45.2% increase in 16 years
• Falls to lower level $5.5 billion 9.9% increase in 12 years
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29. A Company 2014
• A contractor was hired to review all potential
fall hazards at the site.
• In response to this review, the site has
installed fall protection on the roof to protect
HVAC, and other contract employees, from
falls.
• Guardrails were installed at edges and
designated walkways to the HVAC units were
delineated.
• Guardrails were also installed around
skylights.

30. February 2015
• Genie
• Allows a user to exit the platform and work
comfortably around the outside of the
platform with a 6-ft lanyard. It attaches to a 6-
or 8-ft platform on all Genie telescopic and
articulating boom lifts with lift heights higher
than 40 ft., with the exception of the S-125HD
model.

31. JLG
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32. June 2016
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33. Job Hazard Analysis
• National Tire Shop
• What potential hazard would be
caught with a JHA?
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34. ANSI Lockout Standard

36. Robots and Vision Scanners

37. Robot Safety

38. Industrial Robots
“Programmable multifunctional
mechanical devices designed to move
materials, parts, tools, or specialized
devices through variable programmed
motions to perform a variety of tasks.”
Robots are generally used to perform:
• unsafe
• hazardous
• highly repetitive
• unpleasant tasks
...so that human workers don’t have to.

39. Robot Accidents
Many robot accidents do not
occur under normal operating
conditions, but rather during
programming, maintenance,
repair, testing, or adjustment.
Robots are capable of high-energy movements through
a large volume of space, posing great hazard.

40. Robot Accidents
Types of Accidents:
• Impact or Collision Accidents:
Unpredicted movements, component
malfunctions, unpredicted program
changes related to the robot’s arm or
peripheral equipment.
• Crushing and Trapping Accidents: A
worker’s limb or other body part can be
trapped between, or crushed by, a robot’s
arm and other peripheral equipment.
• Mechanical Parts Accidents: The
breakdown, release, or failure of parts.
• Other Accidents

41. Robot Hazards
Sources of Hazards:
• Human Errors
• Control Errors
• Unauthorized Access
• Mechanical Failure
• Environmental Sources
• Power Systems
• Improper Installation

42. December 2012
• Sterling Heights, MI
• Employee #1, a 38-year-old male
employee with Sodecia Sterling
Heights, was inside a robot work cell
with the interlocked gates closed.
• Employee #1 was struck from behind
by a transfer robot, crushing his chest
and neck.
• Employee was killed in the event.
• Employee #1 had lock attached to his
belt loop - i.e. he did not lock out
before beginning maintenance.

43. July 2015
• Grand Rapids MI
• Grandmother Wanda Holbrook, 57, was
crushed to death by robotic arm at work
• Wanda was working on the production
line when a robotic arm took her by
surprise by entering the section in which
she was stationed.
• The arm hit and crushed her head
against a hitch assembly it was working
on, the lawsuit states.
• It also stated a failure of one or more of
the safety systems or devices had caused
Wanda's death. (per lawsuit)
• William Holbrook has filed a wrongful
death complaint against five robotic
firms responsible for installing and
testing the machinery that killed his
wife.
• $7000 Lockout – Later Dismissed

44. May 2007
• Waverly, NE
• Employee #1 was troubleshooting a
robotic arm used to remove CD
jewel cases from an injection
molding machine, when the arm
cycled and struck the employee.
• He suffered blunt force trauma to
his head and ribs.
• He was transported to the hospital,
where he died two weeks later.

45. July 2009
• City of Industry, CA
• Employee #1 was operating a robotic
palletizer for Golden State Foods, Inc., a
food processor and packager for fast
food restaurants.
• She entered the caged robotic palletizer
cell while the robotic palletizer was
running.
She had not deenergized the equipment.
• Her torso was crushed by the arms of the
robotic palletizer as it attempted to pick
up boxes on the roller conveyor.
• She was killed.

46. Safeguarding Personnel
• Risk Assessment
• should be performed at each stage of
development of a robot system to
determine the appropriate level of
safeguarding
• Safeguarding Devices
• limiting devices, sensors, fixed
barriers, interlocked barrier guards
• Awareness Devices
• chain or rope barriers, flashing lights,
signs, whistles, horns
• Safeguarding the Teacher
• restricting robot speed during
programming in “teach” mode

47. Safeguarding Personnel
• Operator Safeguards
• operator should be outside the robot’s
restricted zone at all times
• Attended Continuous Operation
• when a person is in a robot’s restricted
envelope, the robot should be at slow
speed and in “teach” mode
• Maintenance and Repair Personnel
• perform repairs with robot in manual
or “teach” mode
• Safety Training
• personnel should be able to
demonstrate their competence to
operate robot systems safely

48. Background
• Classes: OSHA 10/30 Hour, Incident
Investigation, Confined Space, Excavation
Safety, Cranes Signaling and Rigging, Fall
Protection, Scaffold Safety, and many more
• Services: Mock OSHA Inspections, Site Safety
Audits, OSHA Litigation Consultation,
• Since 1990, he has trained OSHA compliance
officers in numerous areas including OSHA
policy, safety and health regulations, safety
and health management systems, legal
aspects of investigations, and enforcement
strategies.
48
• 38 years working with
top companies to
achieve ZERO injuries