Monday, October 18, 2010

Lock It Down!

Lockout/Tagout is one of the most important tools we can employ to reduce workplace injuries and fatalities, especially among those that must service equipment as a part of their regular duties. Lockout/Tagout is, quite simply, the process of removing all hazardous energy sources from a piece of equipment, then placing a lock or tag on them to prevent them from being reenergized, either intentionally, or accidentally, until the person that installed the lock is ready.
OSHA states that compliance with the Lockout/Tagout Standard (29 CFR 1910.147) would prevent approximately 120 fatalities (that is one every three days!), and an astonishing 50,000 injuries each year in the United States. Clearly, the need for proper implementation of the process is needed. Lockout/Tagout cannot be thought of as an optional procedure, for use whenever production schedules or personal convenience allow it.
The first step in Lockout/Tagout, like most other safety topics, is to evaluate the workplace for potential hazards. Ideally, this should be done before the need to actually perform Lockout/Tagout has arisen. Employers should look at what procedures are being performed in the facility, and by whom. This will identify what level of training is necessary, and what equipment will be required to safely perform Lockout/Tagout.
The OSHA standards define different levels of responsibility when it comes to Lockout/Tagout roles. The first classification is the ‘Authorized’ employees. These are the employees that actually perform Lockout/Tagout and use it for their personal protection while servicing equipment. These employees should have the highest level of training about Lockout/Tagout, as well as the most intimate knowledge about the equipment they will be servicing.
The next level is the ‘Affected’ employees. These are employees that use the machines or equipment that is being serviced, or workers whose job requires them to be in the immediate area as equipment that is locked out. Affected employees do not perform Lockout/Tagout, nor do they perform any servicing or maintenance on the equipment that may expose them to hazards. Their main responsibility with Lockout/Tagout is to recognize when the procedure is in place, and leave it alone! They are not authorized to remove or tamper with the Lockout/Tagout procedures in place.
The next step in implementing an effective program is to identify any equipment that is served by more than one energy source. This equipment will require written Energy Control Procedures, specific to that equipment, that detail how an orderly shut-down, proper energy isolation, and verification testing should be performed. It may be necessary to consult with the manufacturer, or even hire an independent consultant to assist with getting all the steps in the right order as well as insuring proper documentation of the program. Remember, properly implementing these Energy Control Procedures should be the highest priority, since someone’s safety may be at stake.
Lockout/Tagout training should be performed so that each employee understands his role and responsibilities to the program. Annual refresher training should be performed also, just to be sure that everyone is still on the same page. This is also a good time to review the Energy Control Procedures to make sure they are still relevant, and that they still protect workers like they are designed to do.
Lockout/Tagout is not an optional program. OSHA mandates that all equipment be completely removed from its energy source before workers engage in any operation that may injure them if the equipment were to restart. Also, there is no time limit placed on the operation, so a worker clearing a jam that takes four seconds deserves the same amount of protection as one overhauling a machine that takes four weeks. In either case the equipment must be completely removed from its energy source before work can proceed. It’s the law, and it’s the right thing to do to guard worker safety.

-Jason

Monday, October 4, 2010

Is Your Forklift Program Lifting Its Own Weight?

Forklifts and other Powered Industrial Trucks are vital to industry in the United States. We rely on this equipment to lift, stack, tier, pull, and push material in a wide variety of applications. Just as we maintain the equipment itself, we must also remember to maintain the operators. While a forklift is a valuable tool when used properly, just like an automobile, it can be a deadly tool when used improperly.
Forklift accidents account for about 95,000 injuries and about 100 workplace fatalities each year; an appalling figure. Many of these incidents can be traced to operators with inadequate training. OSHA requires in 29 CFR 1910.178 that operators receive training and certification at least every three years in order to remain proficient. Awareness of this requirement is usually not a problem in large warehousing facilities, but smaller operations that have only one or two forklifts that may not even get used every day sometimes are unaware of the standard.
Some operations have a great enough need for certifications that they maintain an in-house trainer to handle certifications as needed. For other operations, that may not be practical. Private safety trainers and consultants should be able to provide this service, or the equipment supplier may be able to help arrange training.
The training must include several elements to fulfill the requirements of the standard. To begin with, it must be conducted by a qualified trainer. If the trainer is unsure of the requirements and proper operating procedures, then the students may not get the best investment of their time. The training must also include a classroom portion with a written test. This is the opportunity for the trainer to personalize the training to address the needs and unique hazards that are present at each worksite. This should include a discussion of the particular operation, as well as a discussion of the particular equipment that the workers will use onsite. The written test is useful to evaluate comprehension of the material. Keep in mind, that if workers are present who do not speak English, a trainer should be chosen who can effectively communicate in their native language. This includes having written tests that are translated as well. We want to avoid the scenario where workers who do not understand the presentation sit in the back and nod their heads because they are too afraid to let someone know they do not speak the language.
After the classroom portion of the training is over, it is time to perform the practical evaluation of the participant’s skill. They need to drive the forklift. An evaluation should be set up by the instructor that will allow her to observe the trainees go through a series of maneuvers to demonstrate their efficiency. There is no required set of motions, but each operator should have to perform motions similar to the ones they will use in the performance of duties. Observing their familiarity with the equipment, lifting, steering, braking, adjusting forks, etc., should all be a part of this section.
After the instructor is satisfied with the operators’ performances, a certification may be issued that lasts for a maximum of three years. After that time, a complete recertification must occur. A separate certification should be issued for each type of equipment the operator uses, and a separate practical evaluation performed for each type, also.
Retraining may be required if new equipment or new hazards are introduced that affect forklift operations. Retraining may also be needed if operators show that they are unable, or unwilling, to follow safe operating procedures.
Proper forklift operator certification is required under the OSHA Performance Standard, and the training is not difficult to come by. With a little involvement by the employer, and the employee, the workplace can be made that much safer, which is our ultimate goal!

-Jason