LOUISVILLE, Ky. (WDRB) -- It's only been about a month since family and friends lost Melissa Stephens at a car parts factory in Jeffersonville.
The mother was working at Autoneum when the coroner said she was involved in an accident with a machine and died.
"I'm not shocked that someone died there," said Fayth Hill, a former employee at Autoneum. "I am shocked at who it was, just because I knew her."
"I wouldn't call it a safe spot to work."
It looks like, at least on some levels, the Indiana Occupational Safety and Health Administration agrees with her.
OSHA dinged Autoneum with several safety violations totaling $224,000. The scathing report obtained by WDRB News spells out serious concerns at the River Ridge plant.
Here are the highlights:
- Employees wore loose clothing and other items that could be drawn into machines.
- Machines had pulleys and belts that exposed employees to hazards
- Employees weren't properly trained to shut down machines in case of an emergency.
Those are the first wave of violations levied against Autoneum in southern Indiana, but the company is no stranger to OSHA. Since 2013, the company has now been sited for 38 violations. Fines total close to $900,000.
"I'm extremely surprised that it's not a bigger number," Hall said.
Autoneum responded to the fines at the Jeffersonville plant Tuesday with a statement. It reads, in part:
"As a globally producing company, we constantly monitor our production procedures and define necessary actions to ensure a safe working environment. As an example, our production staff is regularly trained at all locations on occupational risks and hazards. This includes the correct operating of machinery and equipment."
=====================
JEFFERSONVILLE, Ind. (WDRB) -- OSHA is investigating a southern Indiana manufacturing plant after a worker died on the job.
The Clark County Coroner said Melissa Stephens, 44, died from injuries after an accident with a machine. It happened at the Autoneum North America facility at River Ridge in Jeffersonville on Saturday night.
"I'm not shocked that someone died there," Fayth Hall said. "I am shocked at who it was, just because I knew her."
Hall worked at the plant with Stephens earlier this year making car parts for Ford and GM. She said she decided to leave her job because of unsafe working conditions.
"There's so many things that shouldn't be going on," Hall said. "It's a very unsafe environment."
Hall said she isn't shocked Stephens' death involved a machine. She said employees don't get enough training to operate the machines safely.
"I was not taught whatsoever how to do a machine," she said. "They threw me on to the line, and I was expected to know what I was going to do, which is extremely dangerous."
The Jeffersonville plant has a clean record, but nine OSHA investigations have turned up 33 serious safety violations at other North American Autoneum plants in the last four years alone.
In May, OSHA fined Autoneum $500,000 after a worker lost a hand and part of his arm at an Ohio facility. Those violations were deemed "willful," meaning the company knew it wasn't complying with safety laws and/or acted with plain indifference toward employee safety.
The Swiss-based company sent WDRB News the following statement:
“We confirm that a fatal accident happened Saturday night at the Autoneum plant in Jeffersonville, Indiana. We immediately started an internal investigation and work closely together with various authorities. As a globally producing company, Autoneum complies with occupational health and safety regulations at all locations and is committed to the highest local and international standards in this area. We are deeply affected by this accident and our thoughts go out to the family of our colleague.”A spokesperson for the Indiana Occupational Health and Safety Administration confirms the agency is conducting an investigation into the incident at Autoneum.
- Dr. Anahid Rickmann, Head of Corporate Communications & Responsibility
=====================
http://metroforensics.blogspot.com/2017/10/worker-melissa-stephens-44-was-crushed.html
Monday, October 23, 2017
Worker Melissa Stephens, 44, was crushed to death by machinery at the Autoneum North America plant in Jeffersonville, KY
JEFFERSONVILLE, IN — Clark County Coroner Billy Scott has ruled multiple blunt-force trauma as the preliminary cause of death for an employee who died at a plant in the River Ridge Commerce Center Saturday.
Melissa Stephens, 44, died late Saturday after an accident with a machine at Autoneum, a Swiss-based company that manufactures GM and Ford parts, Scott said.
Jeffersonville Police responded to the incident just after midnight Sunday. But since it is not believed to be a criminal death investigation, it is now in the hands of the Clark County Coroner's Office and the Occupational Safety and Health Administration (OSHA.)
Stephens' autopsy was performed early Monday morning, Scott said. Official results will take a few weeks, pending a toxicology report.
Hollis said Stephens' death is the second fatality within the past year at River Ridge. In November, 33-year-old employee of Florida-based construction company Gardner-Watson fell 50 feet to his death from a ladder.
In May, Autoneum's Toledo, Ohio, plant was cited nearly $570,000 for violations following the amputation of an employee's hand, wrist and part of his forearm. Included in the citation were three “willful violations,” which means the company was aware of them, and two repeated violations.
The company provided a statement today regarding the death at the Jeffersonville facility.
"We confirm that a fatal accident happened Saturday night at the Autoneum plant in Jeffersonville, Indiana," the statement read. "We immediately started an internal investigation and work closely together with various authorities. As a globally producing company, Autoneum complies with occupational health and safety regulations at all locations and is committed to the highest local and international standards in this area.
"We are deeply affected by this accident and our thoughts go out to the family of our colleague."
=======================
JEFFERSONVILLE, IN (WAVE) - Jeffersonville police are investigating a death at an auto machine factory.
A woman was killed Saturday night at Autoneum North America, located on River Ridge Parkway. The company makes parts for General Motors and Ford.
The incident involved machinery, according to police, and they believe it was an accident.
The Clark County Coroner's Office identified the victim as Melissa Stephens, 44. Her autopsy is scheduled for Monday.
WAVE 3 News reached out the company, which is based in Switzerland, but have not yet received a comment.
OSHA is investigating Stephens' death.
Looking into the company's records, we found hundreds of thousands of dollars in fines for safety violations.
We talked to two former Autoneum employees. One man said he quit the auto parts factory because of what he called dangerous working conditions.
Autoneum has five factories in the US. We found the company has faced numerous OSHA violations before at its other plants - 33 in the past four years alone.
We did not find not find any from the Jeffersonville plant. But, earlier this year, the company was fined nearly $600,000 after a worker lost an arm in a shredder in Ohio. OSHA also reported the shredder did not have a proper guard to avoid injury.
OSHA stated three of the violations were willful, meaning the company was aware of the problem.
Autoneum North America, Inc.
100 River Ridge Parkway
Jeffersonville, Indiana 47130 - USA
Telephone: 812-590-1950
Website: www.autoneum.com
Jeffersonville, Indiana 47130 - USA
Telephone: 812-590-1950
Website: www.autoneum.com
Under construction. Products to include automotive
sound and thermal management materials and floor carpets. Site
activities to include manufacturing and distribution.
Employees: 220
Facility size: 300,000 ft.²
======================
Updated: Oct 22, 2017 7:42 PM EST
LOUISVILLE, Ky. (WDRB) -- Jeffersonville Police are conducting a death investigation after an employee died at a River Ridge auto parts plant. The worker was crushed to death by machinery.
Officers responded to Autoneum North America on River Ridge Parkway in Jeffersonville late Saturday night.
Police tell WDRB no foul play is suspected in the employee's death.
No other information was immediately available as the investigation is ongoing.
This story will be updated as more information becomes available.
==============================
Machine Guarding
Machine Guards are designed to protect you from the hazards of moving machinery parts.
Basics of Machine Safeguarding
Crushed hands and arms, severed fingers, blindness -- the list of possible machinery- related
injuries is as long as it is horrifying. There seem to be as many hazards created by moving machine
parts as there are types of machines. Safeguards are essential for protecting workers from needless
and preventable injuries.
A good rule to remember is: Any machine part, function, or process which many cause injury must be
safeguarded. When the operation of a machine or accidental contact with it can injure the operator
or others in the vicinity, the hazards must be either controlled or eliminated.
Correct Guarding Possible Death No Guard
The absence or incorrect use of machine and tools guards can cause injury or death. Without proper
guarding, loose clothing or hair can get caught by rotating or reciprocating mechanisms.
Fingers and hands can get caught in rollers, gears, pulleys, belts and in chain drives. Coworkers
working near moving machine parts are at risk of getting cut, sheared, or crushed
This training handout will describe common hazards associated with moving machinery parts and the
requirements and safeguards that should be used to minimize your risk of injury
This training will illustrate scenarios so that you will be able to:
• Identify the mechanical hazards common to all machines
• Recognize the types of guards used to control machine hazards
• Recognize different types of safety devices used to control machine hazards
• Describe other safeguards that may be used to minimize your risk of machine- related injury
• Identify types of personal protective equipment that you may use while operating industrial
machinery.
Regulatory Background
Any machine part, function, or process which may cause injury must be safeguarded When the
operation of a machine or accidental contact with can injure the operator or others in the
vicinity, the hazards must either be controlled or eliminated
Workers who operate and machine machines suffer approximately 18,000 injuries which include
amputations, lacerations, crushing injuries and abrasions, and 800 deaths per year OSHA requires
that machine guarding be provided and maintained in a manner sufficient to protect machine
operators and other persons present in machine areas
The Occupational Safety and Health administration (OSHA) requirements can be found at www.OSHA.gov
in the Code of Regulations CFR 1910 Subparts O & P.
The standard outlines definitions, general requirements, and standards for safeguarding different
types of industry machinery.
Some states also have State Approved OSHA Programs and have adopted their own state specific
standards and enforcement for machine guarding. You can find out if your state has their own OSHA
Program by going to http://www.osha.gov/ and selecting State Programs from the left menu pane.
What is a State OSHA Program?
Section 18 of the Occupational Safety and Health Act of 1970
(The Act) Encourages States to develop and operate their own job safety and health programs. OSHA
approves and monitors State plans and provides up to 50 percent of an approved plan's operating
costs.
There are currently 22 states and jurisdictions operating complete state plans (covering both the
private sector and state and local government employees) and 4 - Connecticut, New Jersey, New York
and the Virgin Islands - which cover public employees only. (Eight other States were approved at
one time but subsequently withdrew their programs).The following are states with OSHA Programs:
Alaska, Arizona, California, Connecticut, Hawaii, Indiana, Iowa, Kentucky, Maryland, Michigan.
Minnesota, Nevada, New Mexico, New Jersey, New York, North Carolina, Oregon, Puerto Rico, South
Carolina, Tennessee, Utah, Vermont, Virgin Islands, Virginia, Washington and Wyoming.
Machine Guarding - Must be visible and stated
Machine Guarding Standards
Machine guarding hazards are addressed in specific standards for the general industry, marine
terminals, longshoring, and the construction and agriculture industries. This page highlights OSHA
standards, Federal Registers (rules, proposed rules, and notices), directives (instructions for
compliance officers), standard interpretations (official letters of interpretation of the
standards), and national consensus standards related to machine guarding.
Training Requirements
Training is a critical part of any effort to protect against machine-related hazards.
Your supervisor is responsible for providing you training when any new safeguards are put into
service or when anyone is assigned to a new machine or operation.
At a minimum, your training should cover the following topics:
o A description and identification of the hazards associated with the machine
o A description of the safeguards and their functions
o Instruction on how to use the safeguards
o Instruction on how, and under what circumstances safeguards may be removed, and by whom
o Instruction on what to do if a safeguard is missing, damaged, or inadequate.
Mechanical Hazards
All machines have three (3) fundamental hazards:
• Point of operation, the area of a machine where the work is being performed
• Power transmission apparatuses, all components of the mechanical system that conduct energy to
the part of the machine tool doing the work including flywheels, pulleys, belts, chains,
couplings, spindles, cams, gears, connecting rods and any other machine components that transmit
energy.
• Other moving parts such as machine components that move during the machine operation that are
reciprocating, rotating, ad transverse moving parts, and auxiliary machine parts
Despite machines having the same basic characteristics, their safeguarding need vary widely due to
their differences in design an operator involvement.
Mechanical Motions and Actions
There are many mechanical motions and actions that can be hazardous. Recognizing these hazards,
alone or in combinations, is the first step in protecting yourself
Basic types of hazardous mechanical motions and actions:
Motions included are:
Rotating (including in-running nip or pinch points)
Reciprocating
Transversing motions
Actions included are:
Cutting
Punching
Shearing
Bending
All mechanical motion is potentially dangerous and hazardous
Nip Points - One of the most hazardous is in-running nip points or "pinch points" which occurs When
two parts move together and at least one moves in a rotary or circular motion that gears, rollers,
belt drives and pulleys generate. Nip points are also created between rotating and tangentially
moving parts. Some examples would be: the point of contact between a power transmission belt and
its pulley, a chain and a sprocket, and a rack and pinion.
Rotating - Circular movement of couplings, cams, clutches, flywheels, and spindles as well as shaft
ends and rotating collars that may catch your clothing or otherwise force a body part into a
dangerous location. Rotating motion can be dangerous; even smooth, slowly rotating shafts can grip
clothing, and through mere skin contact force an arm or hand into a dangerous position. Injuries
due to contact with rotating parts can be severe. Collars, couplings, cams, clutches, flywheels,
shaft ends, spindles, meshing gears, and horizontal or vertical shafting are some examples of
common rotating mechanisms which may be hazardous. The danger increases when projections such as
set screws, bolts, nicks, abrasions, and projecting keys or set screws are exposed on rotating
parts
Reciprocating is a back and forth or up and down action that may strike or entrap you between a
moving part and a fixed object. Reciprocating motions may be hazardous because, during the
back-and-forth or up-and-down motion, a worker may be struck by or caught between a moving and a
stationary part.
Transversing is movement in a straight, continuous line that may strike or catch you in a pinch or
shear point created between the moving part and a fixed object. Moving belt conveyor type machines
are a very common type of Transversing motion.
Cutting is action generated during sawing, boring, drilling, milling, slicing and slitting Cutting
action may involve rotating, reciprocating, or transverse motion. The danger of cutting action
exists at the point of operation where finger, arm and body injuries can occur and where flying
chips or scrap material can strike the head, particularly in the area of the eyes or face. Such
hazards are present at the point of operation in cutting wood, metal, or other materials. Examples
of mechanisms involving cutting hazards include bandsaws, circular saws, boring or drilling
machines, turning machines (lathes), or milling machines.
Punching action results when power is applied to a slide (ram) for the purpose of blanking,
drawing, or stamping metal or other materials. The danger of this type of action occurs at the
point of operation where stock is inserted, held, and withdrawn by hand
Shearing action involves applying power to a slide or knife in order to trim or shear metal or
other materials. A hazard occurs at the point of operation where stock is actually inserted, held,
and withdrawn. Examples of machines used for shearing operations are mechanically, hydraulically,
or pneumatically powered shears.
Bending action occurs when power is applied to a slide to draw or form metal or other materials
into various shapes. Bending action results when power is applied to a slide in order to draw or
stamp metal or other materials. A hazard occurs at the point of operation where stock is inserted,
held, and withdrawn. Equipment that uses bending action includes power presses, press brakes, and
tubing benders.
You should also be aware of non mechanical hazards such as:
Power sources - Electrical and Hydraulic
All power sources for machines are potential sources of danger. When using electrically powered or
controlled machinery, the equipment as well as the electrical system itself must be properly
grounded. Replacing frayed, exposed, or old wiring will also help protect you and others from
electrical shock or electrocution. High pressure
systems also need to be carefully inspected and put on a systematic maintenance schedule to prevent
possible failure from pulsation, vibration, or leaks. Such a failure could cause explosions, flying
objects and a variety of other things.
Unwanted Exposure to Sound and Noise
Machinery produces unwanted sound or noise which can result in a variety of hazards to you and
others in close proximity. Research has linked noise to a wide range of harmful health effects,
from hearing loss and aural pain to nausea, fatigue, reduced muscle control, and emotional
disturbance. Engineering controls such as the use of sound
dampening materials, and hearing protection, can help control the harmful effects of noise.
Administration controls such as temporarily removing the operator from the noise source can also be
effective.
Effects of sound and noise exposure - please note that when the daily noise exposure is composed of
two or more periods of noise exposure of different levels, their combined effect should be
considered as opposed to each singularly.
Cutting Fluids, Coolants, and Other Potentially Harmful Substances
Because some machines require the use of cutting fluids, coolants, and other potentially harmful
substances, operators, maintenance personnel, and others in the immediate area may need additional
protection. These substances can cause ailments ranging from dermatitis to serious illnesses and
diseases. Specially constructed safeguards, ventilation, and personal protective equipment and
clothing are possible temporary solutions to the problem of machine tool related chemical hazards,
but only until these hazards can be better controlled or eliminated from the workplace
Requirements and Safeguards
At a minimum, safeguards must meet these following general requirements:
Prevent contact - Safeguards must minimize the possibility of you or your coworkers placing your
hands into hazardous moving parts
Remain secure - You should not be able to easily remove or tamper with the safeguard Protect from
falling objects - Safeguards should ensure that no objects can fall into moving parts
Create NO new hazards - A Safeguard defeats its purpose if it creates a hazard of its own Create no
interference - A safeguard should not create an unacceptable obstruction Allow safe maintenance
and lubrication - It should be possible to lubricate the machine without removing the safe guard
OSHA Fatal Fact: In July of 1999, a worker using a hydraulic press to punch holes in a piece of
steel was fatally injured when a piece of steel debris struck him in the neck.
When the hydraulic press attempted to punch through the hardened steel plate, the punch bit
shattered. According to an OSHA investigator, the guard on the machine had been removed sometime
prior to the accident and had not been replaced.
Machine Safeguards can be grouped under (5) five general classifications:
1. Guards
2. Safety devices
3. Location and distance safeguards
4. Potential feeding and ejection methods
5. Miscellaneous aids
Guards
Guards are barriers that prevent access to danger areas. There are 4 general types of guards that
all workers should recognize.
Fixed Guards are a permanent part of the machine. It is not dependent upon moving parts to perform
its intended function. This guard is usually preferable to other types.
Interlocked Guards
When this type of guard is opened or removed, the sensor or trip mechanism automatically shuts off
the power or disables the machine from operating. The machine will not start until the guard is in
its proper place and position.
Adjustable Guards
Adjustable guards are useful because they allow flexibility for different size and shape
applications of parts or units. Many machines perform the same type of function on different types
of size material. Being able to adjust the guard allows for the machine to perform the function on
varied sized of material by moving the guard to fit the material size.
Self Adjusting Guards
Sensors determine the size of the source material enabling the size of the guard openings to adjust
the machine guards to the size of the material being moved through the machine.
Guard Construction and Implementation
Guards should be designed and installed by the manufacturer or design engineers of the machine. By
following this rule you will have two main advantages:
• The guard will comply with the integrity, design and function of the machine
• The guard can be designed to add stability and strength to the machine and possibly provide an
additional purpose. NEVER alter the machine itself.
Sometimes it is necessary to fabricate guards or contract a fabricator to construct a guard for the
application needed
The plus side of user built or contracted built guards:
• With older machinery the manufacturer may no longer be in business and the replacement parts
and additional engineering may no longer be available. Therefore fabricating a guard may be the
only choice especially in power plants where machinery is not powered by individual motor
assemblies.
• It is always best to contract skilled personnel to design and fabricate the guards who are
familiar with the operation of the machine and the safeguards needed
• The guards can be designed and built to for unique situations and tailored for application
changes.
The down side of user built or contracted built guards:
• The design may not be totally compatible to the design, integrity and function of the machine.
• The design and construction may not conform to the strength and rigidity required for the
application. OSHA standards require extensive testing before safety Guards are approved for
distribution.
• ANY machine part, function or process which may cause injury must be safeguarded.
• When the operation or use of any machine or accidental contact with it can cause injuries to
you or others in the vicinity, hazards must be controlled OR eliminated.
• If a machine has been designed with a guard in place, DO NOT alter it, tamper with it or remove
it.
Safety Devices
Safety devices help prevent contact with points of operation and can replace or supplement guards
if they are recommended or endorsed by the machine manufacturer.
Depending on the type of safety device:
• It may stop the machine if a worker's hand or any part of the body is accidently placed in a
dangerous area.
• There are restraints that attach to workers to keep them from being able to extend into
dangerous areas during machine operation.
• There are safety devices that require the worker to use 2 hands on machine controls for machine
operation. This also eliminates either hand from accidently being in a danger area or the machine.
• Safety devices can be designed to provide a barrier which is synchronized with the operating
cycle of the machine which will prevent human entry into the danger area during the hazardous part
of the machine cycle.
Various types of presence sensing devices can be used to safeguard many different kinds of machines
as per OSHA 29 CFR 1910.212 and 1910.217.
Presence-Sensing devices use a system of light sources and controls that can interrupt the
machine's operating cycle. If or when the light field is broken, the machine stops and will not
continue operation. These devices are widely used on robots, power presses, textile manufacturing
equipment and many other industrial machines. Presence sensing devices provide maximum visibility
of a machine's danger zone. These types of devices are to be used only on machines which can be
stopped before the operator can reach the danger area.
Radio Frequency devices use a radio beam that is a part of the machine control circuit. the
operating principal is similar to presence-sensing devices. However, accident records and safety
analyses of radiofrequency presence sensing devices show that improper application, use, selection,
design or mounting of these devices can result in serious accidents. It is recommended that
radiofrequency presence sensing devices not be used as the primary safeguards or only safeguards
for workers exposed to serious hazards.
The basic function of a radiofrequency presence sensing device is to interrupt a machine's
operating cycle when an object is detected within the device's sensing field. For the device to be
effective, it must:
Radio Frequency Identification
electric conceptual compositions
1. be installed and tuned so that effective sensing occurs at least at a minimum safe distance;
2. be able to detect penetration of a minimum hand size;
3. stop or prevent the operation of a machine as long as any part of an employee's body is within
the machine's danger zone;
4. be interlocked with other guarding devices or have fixed guards to prevent human access to a
machine's danger zone except through the sensing field;
5. protect exposed employees during all phases of machine operation including start-up, shutdown,
and maintenance; and
6. generate no false "safe-to-operate" signals and ignore received false "safe-to-operate" signals
due to component malfunction or environmental conditions such as unexpected electrical or magnetic
fields, humidity, and moisture.
A radiofrequency presence sensing device may not be able to provide effective protection if:
1. it is not installed and tuned so that its sensing field is at a safe distance;
2. penetrating object is too small to be detected in time by the sensing field;
3. a penetrating object is between the field and the danger zone;
4. its source of power fails while the machine remains operative;
5. it is installed on equipment not designed to stop upon field interruption at any point of the
machine's operating cycle, such as full revolution presses.
Capacitance Proximity Sensing (CPS)
CPS devices (radiofrequency presence sensing devices) consist of a control unit, a coupler, a
sensor antenna and a cable connecting the control unit to the sensor. The antenna should have a
geometrical shape that makes the generated sensing field form an envelope around the space where
human detection is desired. This sensor antenna is made of electrical conducting material and is
isolated from the ground. An oscillating electrical signal in the radiofrequency range of 150 - 400
KHz is generated in the control unit and sent through the cable and coupler to the sensor. At the
sensor antenna the signal creates an electric potential and generates an electromagnetic field. The
developed field can be much larger than the volume defined by the antenna. The shape of the field
is affected by the location of objects within its boundaries and by shielding at the sensor, and is
not normally well-defined. Physical changes in the space surrounding the antenna alter this
electromagnetic field. An electronic bridge circuit incorporating an adjustable reference
capacitance is used to detect changes in the field capacitance. At a tuned level the bridge
becomes unbalanced, thus triggering machine stoppage.
Studies have shown that well-grounded conductors (people) are more easily detected by CPS system
because a grounded conductor causes a greater change in capacitance in a CPS detection bridge than
a weakly-grounded conductor. In fact, ungrounded conductors may not be detected and poorly grounded
objects must penetrate the field more deeply for CPS devices to detect the presence of such
objects. Attention should be paid to potential problem situations such as those where employees can
move from ground to an insulated platform while remaining in an antenna's detection space.
Detectable changes of the sensing field in the presence of an operator may diminish when the
operator is isolated from ground. Intermittent energizing of outside electric fields (such as those
from electric motors or power supplies) and the movement of objects into the sensing field (such as
maintenance gear) also should be checked to insure that they do not change the capacitance of the
CPS system. Changes in machine tool or die layout may also adversely affect the detection field.
CPS devices employ a "sensitivity" control as an operating adjustment to compensate for changes in
the field due to added or subtracted shielding such as tooling and support hardware. This
adjustment has the effect of moving an effective sensing point toward or away from a machine's
danger zone. Unfortunately, this can permit effective sensing at less than a safe distance. Also,
holes in the sensing field can be created if the effective sensing point is collapsed to the
antenna. In this case the system might not detect the presence of an operator's arm in the sensing
field. The safety distance between the sensing plane and the danger point cannot be set upon
initial installation, but must be reset for each application.
Recommendation:
Specific standards have not been adopted for the installation, adjustment, and maintenance of
radiofrequency presence sensing devices. Employers using such devices should have had safety hazard
analyses performed to determine potential failures or limitations of the devices in their
applications. Employers should be aware that the performance of a CPS device may be affected as
environmental and physical conditions are changed.
In 1979, National Institute for Occupational Safety and Health (NIOSH) issued a warning on the use
of radiofrequency presence sensing devices. The warning emphasizes that the following procedures be
followed:
1. Care must be taken to set a device's sensitivity for the operator's grounded condition and allow
for variations in the operator's working position during a workday.
2. Supervisors and workers should avoid drastic grounding changes once sensitivity is set and a
device is in use. This includes changes in what the operator is standing or seated on.
3. Manufacturer's instructions should be followed carefully in the construction and placement of
radiofrequency antennas.
4. The manufacturer of a device should be consulted about specific problems, such as extreme
sensitivity variations in particular machine applications.
Because of the uncertainties involved with the ability of radiofrequency detectors to measure
intrusion accurately due to ground changes, field interference and other physical and environmental
conditions, CPS devices should not be used as the primary or only safeguard to protect workers who
are frequently exposed to a serious hazard. When used for applications involving infrequent human
intervention such as perimeter guarding, CPS devices may provide adequate protection. Changes in
sensing distance may not be critical if there is no need for an operator to normally reach into the
danger zone. A combination of a CPS device and an automatic feeding device or other safe guarding
method provides better protection.
Compliance and consultation personnel must be aware of the hazard addressed in this bulletin.
Please disseminate this information to Area Offices, State Plan States and Consultation Projects. A
companion information bulletin is being prepared on photoelectric type presence sensing devices and
will be issued in the very near future.
Electromechanical Sensing Uses a probe or contact bar -
Electromagnet Probe
- which descends to a presence distance when you start the machine cycle. If an obstruction
prevents it from descending its full distance, the control circuit won't allow the machine to
start.
Pullback devices utilize a series of cables attached to the operator's hands, wrists, and/or arms.
This type of device is primarily used on machines with stroking action. When the slide/ram is up
between cycles, the operator is allowed access to the point of operation. When the slide/ram begins
to cycle by starting its descent, a mechanical linkage automatically assures withdrawal of the
hands from the point of operation.
Safe guarding action
As the machine begins to cycle, the operator's hands are pulled out of the danger area
Advantages
Eliminates the need for auxiliary barriers or other interferences at the danger area
Disadvantages
• Limits Movement of operator
• May obstruct work space around operator
• Adjustments must be made for specific operations and for each individual
• Requires frequent inspections and regular maintenance
• Requires close supervision of the operator's use of the equipment
Safety trip controls provide a quick means for deactivating the machine in an emergency situation.
A pressure-sensitive body bar, when depressed, will deactivate the machine. If the operator or
anyone trips, loses balance, or is drawn toward the machine, applying pressure to the bar will stop
the operation. The positioning of the bar, therefore, is critical. It must stop the machine before
a part of the employee's body reaches the danger area.
Safe Guard Action
• Stops machines when in use
Advantage
• Simplistic to use
Disadvantages
• All controls must be manually activated
• May be difficult to activate controls because of their location
• Only protects the operator
• May require special fixtures to hold work
• May require a machine brake
The two-hand control requires constant, concurrent pressure by the operator to activate the
machine. This kind of control requires a part-revolution clutch, brake, and a brake monitor if used
on a power press. With this type of device, the operator's hands are required to be at a safe
location (on control buttons) and at a safe distance from the danger area while the machine
completes its closing cycle.
Safe Guard Action
Concurrent use of both hands is required, preventing the operator from entering the danger area
Advantages
• Operator's hands are at a pre-determined location
• Operator's hands are free to pick up a new part after first half of cycle is completed
Disadvantages
• Requires a partial cycle machine with a brake
• Some two-hand controls can be rendered unsafe by holding with arm or blocking, thereby
permitting one-hand operation
• Protects only the operator
Another variation:
Another variation of two-hand controls devises that require constant pressure by the operator to
activate the machine. The operator's hands are required to be at a safe position or location on the
control buttons and at the specified safe distance from the danger area to enable the machine to
continue and to complete its cycle.
Gates
The gate is a moveable barrier that protects the operator at the point of operation before the
machine cycle can be started. Gates are, in many instances, designed to be operated with each
machine cycle. To be effective, the gate must be interlocked so that the machine will not begin a
cycle unless the gate guard is in place. It must be in the closed position before the machine can
function. If the gate is not permitted to descend to the fully closed position, the press will not
function.
Another potential application of this type of guard is where the gate is a component of a perimeter
safeguarding system. Here the gate may provide protection not only to the operator but to
pedestrian traffic as well.
Safeguard Action
• Provides a barrier between danger area and operator or other personnel
Advantages
• Can prevent reaching into or walking into the danger area
Disadvantages
• May require frequent inspection and regular maintenance
• May interfere with operator's ability to see the work
Planning for Distance and Location Safe Guarding
• Sometimes the location of a machine in the workplace and the distance of the work force and the
machine operators can be documented and used as a safe guard.
• Dangerous moving parts of a machine must be strategically placed to keep the dangerous and
hazardous areas inaccessible and away to general workers and machine operators.
• A thorough hazard analysis of each machine and particular situation is absolutely essential
before attempting this safeguarding technique.
• To consider a part of a machine to be safeguarded by location, the dangerous moving part of a
machine must be so positioned that those areas are not accessible or do not present a hazard to a
worker during the normal operation of the machine.
• Keep in mind that drive mechanisms and power systems will need to be maintained, inspected and
repaired periodically so be careful not to eliminate access to those who need access.
Feeding the Ejection Methods to Improve Operator Safety
• Many feeding and ejection methods do not require the operator to place his or her hands in the
danger area. In some cases, no operator involvement is necessary after the machine is set up. In
other situations, operators can manually feed the stock with the assistance of a feeding mechanism.
Properly designed ejection
methods do not require any operator involvement after the machine starts to function.
• Some feeding and ejection methods may even create hazards themselves. For instance, a robot may
eliminate the need for an operator to be near the machine but may create a new hazard itself by the
movement of its arm.
• Using these feeding and ejection methods does not eliminate the need for guards and devices.
Guards and devices must be used wherever they are necessary and possible in order to provide
protection from exposure to hazards.
Types of feeding and ejection methods...
Automatic feeds reduce the exposure of the operator during the work process, and sometimes do not
require any effort by the operator after the machine is set up and running
Additional Methods to alert workers to dangerous and Hazardous areas
Despite all of the methods contained in this training they still do not provide complete protection
from machine and machine tool hazards however they do provide an extra margin of safety.
Good old common sense and wise judgments are still needed to operate and work around machinery,
tools and moving parts.
Personal Protective Equipment
Engineering and Administrative Controls are in place to lessen the likelihood that any worker or
general bystander will be injured. These controls are not impervious of fault. Personal Protective
Equipment or (PPE) is the last line of defense still needed to ensure the safest work environment.
Personal Protective Equipment or (PPE) is any device or garment worn by a worker on the job to safe
guard against injuries and or harmful effects of hazardous substances.
Examples of PPE are:
Clothing such as Coveralls, Gloves & Sleeves, outer, chemical-resistant, Gloves, inner,
chemical-resistant, Boots (outer), chemical-resistant steel toe and shank, or Boot-covers, outer,
chemical-resistant (disposable), Hard Hats, Hair Caps and Nets, Face Shields,
Safety Goggles and Safety Glasses, Ear Plugs and Muffs. These types of PPE can be a requirement for
specific applications in general industry.
Please note: Electrical applications require PPE specific to the "Electric Industry".
• Hard Hat: Used to protect the head from impact of bumps or falling objects.
• Caps and Hair Nets: Protect your hair from being entangled in machinery.
• Face Shields, Safety Goggles and Safety Glasses: Protect from chemical splash, particulates
flying, and accidental loose objects that become airborne.
• Hearing Protection: Ear Plugs, Ear Mufflers' can protect your hearing in work environments
where dangerous decibels of noise are constant.
• Gloves & Sleeves: Protect from cuts, light impacts, and rough edges and some chemical exposure.
• Coveralls: Protect general body area from cuts, light impacts, and some chemical exposure.
• Boots: Protect against bumps, light weight falling objects, rough edges and some chemical
exposure.
PPE Hazards
PPE can cause additional hazards. Gloves have been caught in rotating parts, face shields and
goggles can restrict full spectrum vision. Loose fitting coveralls, shirt sleeves and pants can be
caught in moving machinery. Jewelry such as rings, bracelets and necklaces can catch on machine
parts, stock and moving machinery. It is best not to wear jewelry when working near or with moving
machines or machinery.
Education, Experience and Familiarity with the machines, machinery and your working environment is
the key to avert potential injuries, problem areas and hazards. Workers and their management should
make sure that machines are equipped with compliant safety accessories suitable for the hazards of
the machine operator.
Workers and their management should make sure that machine operators are properly trained
Workers and their management should make sure that machines and the safety equipment are inspected
daily to ensure they are in proper working condition.
• Workers and management should make sure there are compliant records that identify the machine,
the required inspection dates specified by the manufacturer, worker, maintenance and management
inspections, the inspection date, problems noted, who performed the inspection and any corrective
action taken.
• Accurate recordkeeping is a requirement and by noting problems assists to ensure that
corrective action will be taken. Manufacturer's specifications should be exercised first and
foremost. Authorized, specifically trained and certified personnel by the manufacturer should
always be consulted prior to any alterations or repairs. In addition their recommendations need to
be kept on record.
Regulations and manufacturer guidelines are in place to so that employers follow an industry
standard to ensure a safe and healthy environment.
Have a safe work day!