Machine Safety: Consequences of not performing risk assessments!

If a machine shop hasn't had an incident or employee injury for 10 years, is that result of an excellent safety culture or simply great luck? Are “hope” and “lack of attention” proactive business strategies?

10/22/2012


“We run an excellent shop because we haven’t had an incident or employee injury for the past ten years!” Are statements like this the result of an excellent safety culture or simply ten years of great luck? Are “hope” or “lack of attention” proactive business strategies?

 

I would expect your answer to be – NO!

 

It basic nature that businesses don’t want incidents to occur.  And, at the same time employees don’t want to be hurt. Businesses generally, some only when confronted, don’t wish for exposure to unneeded regulation, un-scheduled machine downtime, employee injuries, costly liabilities or the cost burdens associated with these issues. Yet, in my opinion, these are some of the negative results a business can expect as consequences of avoiding the required risk assessments for their machinery operations.

 

Some of the potential liabilities of exposure (avoidable consequences) might be:

- Timing – Too many businesses still avoid the issue of compliance to the risk assessment requirement which extends to existing, new or modified equipment. The sooner the better to meet compliance requirements and avoid citations.

- Miss-applied devices – quite often safety devices are provided but are miss-applied because a hazard level was not properly assessed. For example, a Cat 4 hazard could require a control reliable solution involving a Cat 4 safety rated switch with redundant contacts. A miss-applied device in this example could include; a single standard interlock switch, safety rated devices below Cat 4, or an application which is not control reliable.

- Foreseeable misuse – a properly conducted machine guarding risk assessment will typically uncover misuse situations like; equipment malfunction, unauthorized process material, operating tooling beyond its useful life, unexpected loss of power, and reach over – under – around - or through guarding.

- Miss-applied procedure – Lockout/Tagout (LOTO) is frequently misunderstood and/or not always followed as prescribed by OSHA. LOTO incidents are preventable via frequent training, documenting procedures, not permitting shortcuts, and by establishing employee penalties for non compliance.

- Unidentified modes – all modes of operation and their related tasks need to be identified in order to reveal their related hazards. Unidentified modes include; setup, cleanup and preventive maintenance.

 

Have you seen any of these potential liabilities? Can you add any additional potential consequences?

 

The advice of industry experts is to not become aware of the importance of risk assessments only after a serious incident and the resulting OSHA citation, or the legal engagement, or the sever financial expenses which fall directly to your bottom line. “Hope” is not an effective strategy – proactive engaged machine safety leadership is!  

 

Your comments or suggestion are always welcome so please let us know your thoughts. Submit your ideas, experiences, and challenges on this subject in the comments section below. Click on the following text if you don't see a comments box, then scroll down: Machine Safety: Consequences of not performing risk assessments!

 

J.B. Titus, CFSERelated articles:

OSHA – 29 CFR 1910.147, Lockout/Tagout

Machine Safety – does a risk assessment need to be updated for a minor modification to a machine?

Machine Guarding & The Hierarchy of Measures for Hazard Mitigation

Machine Safety: Is OSHA okay with my 'acceptable' risk mitigation?

 

 

Contact: www.jbtitus.com for “Solutions for Machine Safety”.



The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
Additive manufacturing benefits; HMI and sensor tips; System integrator advice; Innovations from the industry
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This article collection contains several articles on how automation and controls are helping human-machine interface (HMI) hardware and software advance.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
Additive manufacturing benefits; HMI and sensor tips; System integrator advice; Innovations from the industry
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This article collection contains several articles on how automation and controls are helping human-machine interface (HMI) hardware and software advance.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Robotic integration and cloud connections; SCADA and cybersecurity; Motor efficiency standards; Open- and closed-loop control; Augmented reality
Controller programming; Safety networks; Enclosure design; Power quality; Safety integrity levels; Increasing process efficiency
Additive manufacturing benefits; HMI and sensor tips; System integrator advice; Innovations from the industry
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This article collection contains several articles on how automation and controls are helping human-machine interface (HMI) hardware and software advance.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

Cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Automation Engineer; Wood Group
System Integrator; Cross Integrated Systems Group
Jose S. Vasquez, Jr.
Fire & Life Safety Engineer; Technip USA Inc.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me