The general perception of machine safety is that it makes the machines stop. Not so, said Pat Barry, a regional marketing leader for Rockwell Automation. “If that were true,” he said, “it means the safest companies would be the least productive. World-class safety, companies have the best safety performance and the best production performance.”
Barry, speaking to a crowded room at the America’s Safest Companies Conference in Atlanta on Oct. 29, said that at its most basic form, machinery safety is “how we keep people safe around machines.” However, he added, appropriate machinery safety does more than keep employees safe.
“Let’s talk about safety and productivity and how those two meld with each other,” Barry suggested. “The fact is, if we have that good, collaborative process (between EHS and production) and we use a good safeguarding process, we can make decisions that will effect both safety and productivity but we have to be deliberate about it. It can’t be a mistake.”
He said that basic machine safeguarding concepts can be boiled down to two basic rules that can be used to keep people safe around machines: Rule No. 1, if you’ve got to get at a machine, shut it off. Rule No. 2, if it’s running, keep people away from it. And, he added, there are federal regulations related to both of these concepts: lockout/tagout and machine guarding.
“When you put those two tools together what we have is a perfectly safe machine that nobody can use, right?” Barry asked, to some laughter from the audience. “We can guard the crap out of it and make sure we lockout/tagout … but then somebody wants to do something silly, like load parts.”
Because in some cases, employees in and around operating machinery, the minor service exception was created. This exception is used in cases where there is a specific set of tasks that are routine and repetitive and they have to be done to keep production running.
In some cases, lockout/tagout – shutting the machine down completely – is an appropriate safety measure. In others, such as those covered by the minor service exception, alternative measures might be the best solution.
As Barry described it, lockout/tagout is an active solution. An employee has to take the steps to shut down and lock out the machine. Alternative measures can be passive, or, as Barry said, “Take what person is doing on the machine anyway and use that to trigger the safeguard.”
As an analogy, he explained that an active safety measure is a seatbelt: you have to place it around your waist and secure it and adjust the shoulder strap. An alternative, passive safety measure is an airbag. All you have to do to trigger it is sit in the seat – something you were going to do anyway.