As noted in several other EHS Works blog posts this week, risk
is a hot topic at ASSE’s Safety 2013 in Las Vegas, NV. Steve Ludwig of Rockwell
Automation and Calvin Beyer of Murray Securus took their turn discussing the topic during “Improving
Manufacturing Safety and Performance Using Integrated Risk Management.”
“Rigorous global safety standards, technology innovations
and thorough risk management techniques now make it possible to develop a more
proactive approach to safety programs,” they explain in their Safety 2013
proceedings paper. Noting that each employer should customize a safety program to
its specific needs, Ludwig and Beyer offer several best practice tips for
taking such an approach.
- Conduct a thorough risk assessment to identify the areas of risk on a machine or within a facility and to pinpoint the best people and technology to help minimize those risks. “Performing a risk assessment upfront helps guide the direction for an effective machine guarding strategy, which is designed to help protect a company’s investment in both personnel and machinery.”
- Reduce potential hazards through design. “Eliminating a hazard by designing a machine to function without putting workers at risk and implementing the right safety technology in the design phase of machine development is more effective than applying physical guarding or monitored access,” Ludwig and Beyer explain. “When machine designers conduct a risk assessment and review the resulting documentation at the earliest stages of inception, they can more effectively reduce hazards.”
- Consider machine guarding. When hazards cannot be designed out, hard guarding in the form of a physical barrier provides more protection at a relatively low cost, they advise. “It’s also important to make sure the solution itself doesn’t cause another hazard.”
- Add advanced controls. “If a hazard cannot be designed out, and physical barriers and guarding are impractical for machine operation, engineers can apply machine controls to detect unsafe machine conditions and place the machine in a safe state to help protect workers.” According to Ludwig and Beyer, there is now a strong trend toward configurable or programmable safety-rated controllers because they provide flexibility and help improve productivity. “Advanced safety systems may also include safety technology embedded in servo devices or variable frequency drives to further improve functionality, while helping maintain a safe working environment.”
- Promote awareness. Workers operating near equipment must be aware of their surroundings. Awareness techniques can include adding appropriate signage, as well as using visual and audible awareness devices and annunciators such as stack lights or alarms. “Awareness devices must be positioned where they will best serve their intended purpose,” say Ludwig and Beyer. “It is also important that audible signals can be heard over normal operating noise, and that they comply with current standards and regulations.”
- Provide training. “Employees must be educated on all types of equipment they will be working with and around.”
- Conduct follow-up assessments. Follow-up assessments verify that the potential risk level was reduced to an acceptable level, Ludwig and Beyer explain.
- Seek experience and expertise. “Suppliers well versed in automation, safety and the current standards and regulatory requirements that apply to the manufacturing environment are highly valuable when embarking on a safety program design or review. These partners should have a thorough understanding of the risk assessment and risk reduction process as well,” say Ludwig and Beyer who conclude, “Creating a safety program with these best practice elements will help set the path for a more proactive approach to reducing risk and improving safety, while increasing productivity. It can also help shift the focus of risk performance from measuring negative outcomes to gauging success based on positive results and forward-looking improvements.”