Machine Safety
Machine safety means more than simply addressing mechanical risks. It also concerns work organization, operator training and knowledge, as well as the selection and use of adequate personal protective equipment for persons performing work in dangerous zones of the different machines they may encounter in their work environment.
A zone is considered dangerous when it jeopardizes workers’ security or physical integrity; a dangerous zone may be inside or around a machine.
Did you know that… machines can kill?*
Each year machines cause close to 13,000 occupational accidents. On average, in Quebec, one worker is injured on a machine every hour. From 1999 to 2003, machines killed 101 workers. An average of 20 workers die each year as a result of an occupational accident involving a machine.
*Source: CSST, DC100-1587 (05-03)
The Santinel inc. Approach
- Analysis (taken from the ISO 121000 standard)
- Inventory and Isolation Dangerous Zones
- Risk Assessment and Control
- Work Environment
- Use of equipment
- Observation of work
- Corrective actions
- Support and Solution
- Assessment of Current Protective Devices
- Identification of Devices to Improve
- Roles and Responsibilities
- Development of Training and Information Programs
- Development or Review of Procedures in Dangerous Zones
- Production and Implementation of a Management Manual
- Coaching
- Dangerous Zone Management Software
Training
Development of Training and Information programs
Specific, Practical Training for Employees, Supervisors, and Lifeguards
Various standards and regulations to consult on lockout
Quebec
In Quebec the Regulation Respecting Occupationnal Health and Safety (LRQ, c.S-2.1, Section XXI) helps us understand the measures that must be taken before performing maintenance or repair work, etc. in the dangerous zones of a machine. (Free translation of the following excerpts.)
§ 1. Guards and protective devices
172. In the present division, as well as in section 323, “dangerous zone” means a zone located inside or around a machine and which may be hazardous to workers’ health, safety or physical integrity.
In the present division, as well as in sections 239 and 267, “guard” means the element of a machine used specifically to isolate a dangerous zone of a machine, for example a safety guard, a cover, a door, or an enclosure.
D. 885-2001, a. 172.
182. Control of the dangerous zone: Subject to section 183, a machine must be so designed and built that it renders its dangerous zones inaccessible. If not, it must be equipped with at least one of the following guards or protective devices:
1- in the event that the dangerous zone is inaccessible to anyone while the machine is on:
| a) |
A barrier guard; |
b) |
A barrier guard equipped with an interlocking device; |
c) |
A latching barrier guard equipped with an interlocking device; |
d) |
A sensitive device; |
2 –in the event that at least one person has access to the dangerous zone of the machine while it is on:
| a) |
A barrier guard equipped with an interlocking device; |
b) |
A latching barrier guard equipped with an interlocking device; |
c) |
An automatic shut-off barrier guard; |
d) |
An adjustable barrier guard; |
e) |
A sensitive device; |
f) |
A two-handed control device. |
D. 885-2001, a. 182.
183. Equivalent safety measures: Section 182 does not apply when it is foreseeable that the installation of a barrier guard or other protective device will result in rendering reasonably impractical the very function the machine was designed to perform, for example a snow remover, a railroad switching system or medical equipment designed to be used directly on patients.
In this case, the employer must take measures which will guarantee equivalent safety to workers, particularly regarding work organization, worker training, operating conditions and operating modes of the machine, as well as personal protective devices and equipment which take into account the absence of barrier guard or other protective device.
D. 885-2001, a. 183.
187. Attributes of a guard: a guard or protective device must not:
| · |
Be an additional source of risks for the workers; |
· |
Be in itself a source of danger, because of the presence of sharp edges, irregularities or wire edges. |
D. 885-2001, a. 187.
When a guard or a protective device is replaced, the spare guard or protective device must provide a level of safety at least equivalent to the original part.
D. 885-2001, a. 188.
189. Actuating devices: Actuating devices must be so designed, installed, and maintained that they prevent accidental machine start-up or shutdown.
D. 885-2001, a. 189.
190. Startup and shutdown devices: Each machine must be equipped with an actuating device allowing startup or shutdown in safe conditions.
D. 885-2001, a. 190.
191. Warning device: When starting-up a machine constitutes a danger for persons in the area, this startup must be announced by a warning device or by any other efficient means of communication.
D. 885-2001, a. 191
192. Emergency shutdown: Subject to section 270, a machine that must be operated by more than one worker must be equipped with an emergency shutdown device.
This device shuts down the machine, according to its nature, as rapidly as possible, without additional risks. It must have the following characteristics:
| · |
it must be located in full view and within range of workers; |
· |
it must be operated in a single motion; |
· |
it must be clearly identified. |
Start-up of the emergency device after use must not in itself cause the machine to start up.
D. 885-2001, a. 192.
193. Groups of machines: A shutdown device on a machine which is part of a group of machines designed to function in tandem with the others, including an emergency shutdown device, must be enabled to shutdown all other machines situated upstream or downstream, if their maintenance is hazardous for worker safety.
D. 885-2001, a. 193.
Source: Regulation Respecting Occupationnal Health and Safety [S-2.1, r.19.01]
Canada
Canada Occupational Health and Safety Regulations (Part XIII, section 13.14 - 13.17):
General requirements for machine guards
13.13 (1) Every machine that has exposed moving, rotating, electrically charged or hot parts or that processes, transports or handles material that constitutes a hazard to an employee shall be equipped with a machine guard that:
| a) |
prevents the employee or any part of his body from coming into contact with the parts or material; |
b) |
prevents access by the employee to the area of exposure to the hazard during the operation of the machine; or |
c) |
makes the machine inoperative if the employee or any part of his clothing is in or near a part of the machine that is likely to cause injury. |
(2) To the extent that is reasonably practicable, a machine guard referred to in subsection (1) shall not be removable.
(3) A machine guard shall be so constructed, installed and maintained that it meets the requirements of subsection (1). DORS/94-263, art. 50(F).
Use, Operation, Repair and Maintenance of Machine Guards
13.14 Machine guards shall be operated, maintained and repaired by a qualified person.
13.15 Subject to section 13.16, where a machine guard is installed on a machine, no person shall use or operate the machine unless the machine guard is in its proper position. DORS/94-263, art. 51.
13.16 Subject to subsection (2), where it is necessary to remove a machine guard from a machine in order to perform repair or maintenance work on the machine, no person shall perform the repair or maintenance work unless the machine has been locked out in accordance with a written lock out procedure provided by the employer.
(2) Where it is not reasonably practicable to lock out a machine referred to in subsection (1) in order to perform repair or maintenance work on the machine, the work may be performed if: a) the person performing the work follows written instructions provided by the employer that will ensure that any hazard to that person is not significantly greater than it would be if the machine had been locked out; and
b) The person performing the work:
(i) obtains a written authorization from the employer each time the work is performed, and
(ii) performs the work under the direct supervision of a qualified person.
13.17 A copy of the instructions referred to in section 13.16 shall be kept readily available by the employer for the information of persons who perform repair and maintenance work on his machines.
Source: CANADA LABOUR CODE, Canada Occupational Health and Safety Regulations, DORS/86-304.
Norms in effect:
- CSA Z432: Safeguarding of Machinery
- CSA Z434: Industrial Robots and Robot Systems-General Safety
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