1. Lockout/Tagout – Alternative Methods (Risk Assessment) W. Jon Wallace, CSP, MBA Workplace Group O: 919.933.5548 E: jwallace@workplacegroup.net

2. Compressed Springs

6. Is this an energy isolating device?

8. Human Safety Blocks?

19. Equipment-Specific Lockout Procedures: 1910.147(c)(4)

20. What about tasks you perform routinely where the equipment must remain energized? Alternative Methods – Risk Assessment

21. A word about risk Risk: Severity X Frequency X Probability

22. Plastic Injection Molding Machine

23. Industrial Robot

24. Example of equipment-retrofit:

25. References for performing Risk Assessment: ANSI Z244.1: Control of Hazardous Energy - Lockout/Tagout and Alternative Methods. ANSI/RIA R15.06: Industrial Robots and Robot Systems - Safety Requirements. ANSI B11.19: 2010 Performance Requirements for Safeguarding OSHA CPL: 02-00-147: The Control of Hazardous Energy – Enforcement Policy and Inspection Procedures

26. Performing Risk Assessment: 1. Identify all tasks: Tasks where equipment must remain energized. 2. Identify Hazards: Electrical; gravity; chemical; pneumatic; etc. 3. Assess Potential Consequences: Worst case scenario (injury).

27. Performing Risk Assessment (Cont’d): 4. Assess potential exposure to hazards. 5. Assess probability of occurrence. 6. Evaluate the risk. 7. Achieve an acceptable level of risk.

28. Let’s Perform an Example: Employee changes tooling on robot once per shift. Existing interlock category: R2C

29. A Word about interlocks (per ANSI/RIA R15.06) : CategoryCircuit Performance R1Control Reliable R2AControl Reliable R2BSingle Channel with monitoring R2CSingle Channel R3ASingle Channel R3BSimple (Simple safety circuit) R4Simple (Simple safety circuit) How to determine interlock: Manufacturer and E&I folks. Increasing Sophistication

30. Back to our example: Employee changes tooling on robot once per shift. Existing interlock category: R2C TaskHazard(s)SeverityExposure (Frequency) AvoidanceProtective Measures Risk Reduction Required Changing tooling on robot. Struck by (moving robot). S2 (Serious injury) E1 (Infrequent) A2 (Not likely to move out of way) Interlock: R2C R2B LEGEND: Summary: Interlock needs to be upgraded from R2C to R2B.

31. Interlock requirement (ANSI/RIA R15.06) Remember: S2; E1; A2.

32. Putting it all together: Evaluate your lockout/tagout program. Implement upgrades as needed. Inventory tasks where equipment must remain energized. Perform risk assessment using ANSI Lockout and Robotic standards. Upgrade safeguards as needed.

33. Conclusion Question/Comments?