1. Identify and mitigate facility risks on an ongoing basis
Every piece of machinery has the potential to cause harm. That’s why the first step to reducing safety incidents is performing a risk assessment for each machine and its interfaces. Today, this process has never been easier. Thanks to new technology, these assessments can be done remotely using software models of the machinery. However, it’s important to note that simply completing a risk assessment isn’t enough to ensure employee safety. To make your facility safer, assessments must be acted upon with targeted mitigation strategies.
A risk assessment is only as good as the safety lifecycle program that follows it. The safety lifecycle is a formalized engineering process used to establish an effective safety system throughout the lifespan of each machine. This involves 1. performing a risk assessment for each machine and interface; 2. identifying steps to mitigate risks; 3. designing the new safety system based on these steps and verifying that it meets requirements; 4. installing the safety system and validating its functionality; and finally, 5. maintaining and making improvements to the system as time goes on. While a risk assessment is the first step towards mitigating potential hazards, each step of the safety lifecycle must be followed to create a resilient mitigation strategy. This is a process that facilities should follow each time a change is made, such as machinery modifications or new worker procedures.
To be effective, a machine safety program must continually evolve with your facility. By revisiting risk assessments and running through the safety lifecycle for each machine and machine interface as standards and technology change, facilities will be able to reduce warehousing safety incidents and meet appropriate international and regional safety regulations.
2. Build an effective lockout/tagout program
Accurate lockout/tagout procedures are essential to any effective machine safety system. These procedures help prevent injuries to service and maintenance employees by outlining the steps required to bring the machines to a zero-energy state so they are safe for maintenance. Lockout/tagout can significantly reduce the risk of safety incidents. According to OSHA, compliance with the lockout/tagout standard helps prevent an estimated 120 fatalities and 50,000 injuries in the U.S. each year.
Many regulatory agencies mandate lockout/tagout standards. In the U.S., this falls under OSHA standard 1910.147, while in Canada this is required by CCHOS standard CSA Z460-20. Despite these requirements, lockout/tagout is one of the regulations most frequently cited by OSHA. Other parts of the world have similar regulations, so it’s important to check with your local authority for specific lockout/tagout requirements.
To work properly, lockout/tagout procedures and employee training must be kept current. A lot can change in a facility over the course of a year, so facilities should review lockout/tagout procedures and associated employee training annually to proactively reduce the risk of employee injury. Not only is this a best practice to help keep your employees safe, but it’s also in your best interest as a company. Workers in the U.S. injured on the job from exposure to hazardous energy lose an average of 24 workdays for recuperation, according to OSHA.
In some countries, conducting annual lockout/tagout reviews is a requirement. In the U.S., OSHA requires that each energy control procedure in a facility be reviewed annually—at least—to confirm it accurately reflects the equipment’s energy sources (1910.147(c)(6)(i)). OSHA also requires a sampling audit of authorized employees to confirm they fully understand their responsibilities and proper usage of lockout/tagout procedures (1910.147(c)(6)(i)(C-D)). Regardless of whether your local authority requires annual audits, reviewing lockout/tagout procedures every year is a best practice to ensure that your facility prioritizes employee safety, stays compliant and minimizes downtime.
Rockwell Automation is a global leader in machine safety
While implementing these procedures may seem daunting, the good news is that you don’t have to do it alone. As one of the largest global industrial safety providers, Rockwell Automation works with organizations every day to create proactive machine safety strategies.
“Our focus is on solving equipment safety challenges, reducing risk and increasing compliance,” says Nuala Mullan, Enterprise Safety Consultant at Rockwell Automation Safety Services. “We help companies develop holistic machine safety plans that address each of these concerns.”
Using a risk assessment as a starting point, Rockwell Automation safety experts help guide organizations through the safety lifecycle for each machine and its interfaces to help ensure that machinery safety keeps up with facility changes. “Safety programs should be constantly iterated upon,” says Linda Freeman, Warehousing Industry Manager at Rockwell Automation. “Risk assessments aren’t a one-time completion task, they’re the foundation for an ongoing safety program.”
Rockwell Automation is here to help facilities take the next step towards improving their machine safety programs, whether that involves finding solutions to machine safety challenges or reviewing lockout/tagout procedures for audit preparation.
Build a safe workplace—set up your business for success now and in the years to come by taking action to build a proactive and resilient machine safety strategy today.
