Although machines are indispensable to modern work, machine related injuries remain a common cause of injuries in plants and other workplaces.
The effects of these machine related injuries can be considerable. Often, the effects range from minor scrapes and scratches to permanent disability and even fatalities.
Because of the possibility of grievous injuries with machine related injuries happening in a matter of seconds, employers have an important responsibility to ensure that they have taken adequate steps to keep their staff safe when they are operating on or working with different equipment.
1) Conduct a facility safety audit
You can only improve what you can measure. Creating an environment with minimal machine related injuries starts with identifying the existing hazards and safety issues in the plant. An integral part of this process is a risk assessment exercise to identify risks of injury that may occur when operating the plant’s machinery, and ways to minimize them.
An audit helps to discover areas of strengths and weaknesses. It focuses attention and resources where needed rather than wasting time interfering with processes that are already functioning efficiently.
The audit should cover two major areas:
- Equipment risk assessment: Before any work equipment or machinery is used or installed, it is advisable to conduct a risk assessment. The assessment will focus on all hazards that could be released during installation, operation, maintenance, and breakdowns – and the possible effects on the operator. You should ask yourself questions like:
- Does the equipment transmit vibrations continually to their hands and arms,
- Does it emit very bright light?
- Are there barriers in place to prevent contact with the moving/rotating/hot parts of the machine?
- Does the machine’s power source (e.g. heat, gas, electricity) pose a risk to workers?
- Are there risks of musculoskeletal problems due to operating the equipment for long hours in a bent or squatting position?
- Work environment risk assessment: Apart from the machinery, the overall work environment should be assessed for safety. Check that employees can work without distractions (e.g. from excessive heat/cold/noise). Is there enough room to move around without colliding with equipment? Is there adequate lighting? Is the plant clean and tidy? Are there any leaking roofs or windows that could allow water to pool on the floor and lead to trip hazards, and so on.
The above information will help with developing a comprehensive safety strategy that incorporates every angle from which problems could arise. That takes us to the next step.
2) Utilize proactive safety controls
From the safety audit information, your focus can now be directed at creating a proactive system that is effective at preventing accidents before they happen. This is achievable through:
In-built safety controls
Most reputable manufacturers provide machines that come with in-built controls that can help to minimize injuries. So, before procuring work equipment, it’s important to check that they come with operating controls that enhance safe usage.
Some common but very effective examples include emergency stop devices, fail-safe features, machine guarding, etc.
Safety policies and procedures
Organizational safety procedures will vary depending on the industry and the kind of equipment being used. But generally, there should be a safety policy that covers details like:
- step-by-step procedures for operating equipment
- permitted clothing around machinery and the use of PPE
- prohibition of alcohol and drug use by machine operators
- when and how to report equipment faults or defects
3) Safety training
Adequate and regular safety training is essential for reducing mechanical hazards. In fact, it is mandatory.
Any worker who will be operating a machine must be made fully aware of all hazards involved – this step is especially critical for new employees. Ideally, this information will be provided through different mediums such as written documents, videos, or safety notices and warnings. Also, there should be adequate oversight function to manage new staff and ensure that safety procedures are being followed correctly.
However, it doesn’t end there. There should be frequent training of older workers as well to avoid some of the common risks associated with complacency.
4) Regular equipment maintenance
Regular equipment maintenance is key for workers’ safety. Several safety-related complications can arise from poor or inadequate maintenance. For one thing, poorly maintained machines are likely to malfunction without warning and put any nearby workers at risk.
Another effect of infrequent maintenance is that there is a higher tendency that the maintenance unit will waste a lot of time grappling with reactive maintenance because of unplanned shutdowns. If the habit of emergency repairs continue long enough, it’s only a matter of time before the organization is left with a crippling amount of deferred maintenance.
A typical problem with rushed or emergency maintenance tasks is that the pressure to complete the repair on time could influence workers to take unsafe shortcuts. For example, a technician working on critical equipment that has shutdown during production may not be careful to follow proper Lockout-Tagout (LOTO) procedures. This often leads to serious safety incidents, especially when electrical equipment is not shut off properly. According to OSHA, LOTO non-compliance is one of the most commonly cited violations in industries.
5) Compliance checks
If you follow the above steps carefully, you could find that a few years have gone by and nobody has been seriously injured at your facility. Several inspections and audits have taken place, and yet no safety issues are pending. The staff is performing their duties routinely with minimal or no reports of non-compliance. But, this is not the time to relax or celebrate. In fact, safety professionals have observed that complacency in an organization is what often leads to a big incident.
This happens because after performing tasks repetitiously, the tendency for boredom or complacency to set in is high. Conducting planned and unplanned inspections at intervals is one of the proven ways to address this problem. Such checks will help to ensure that the agreed procedures are still being followed over time.
In Summary:
Certainly, employers need to be vigilant with safety in their manufacturing facilities because if they fail to take the recommended steps to protect workers from the hazards of machine related injuries, they may be liable for injuries sustained. Nevertheless, creating a safe facility is easier when machine safety is regarded as everybody’s responsibility
Hazardous Waste Management Software
HazMat T&T is a hazardous waste management software solution designed for Environmental Service Companies and companies who generate a large quantity of hazardous waste. The solution tracks hazardous waste from cradle to grave aiding compliance, providing accurate waste inventory, increasing waste handling efficiency, reducing risk and also helps manage waste costs. HazMat T&T Hazardous Waste Management Software can be deployed in a number of deployment scenarios, from Large Hazardous Waste Generators, tracking their hazardous waste at their site to Environmental Service and Waste Management Companies using it track and manage hazardous waste at transfer and disposal sites.
Fire Extinguisher Barcode Inspection Software
Fire Extinguisher Barcode Inspection Software system can be used to manage monthly fire extinguisher inspections, annual inspections and 6 year and 12 year inspections and also general fire safety inspections. Allowing Managers to record safety observations while performing facility tours which can improve overall fire safety. A Fire Extinguisher Inspection Software system that can create corrective actions as a result of inspection failures and allocate these corrective active actions to the appropriate persons, with deadlines for resolution will greatly reduce the time, effort and cost of managing NFPA inspections. Implementing a Fire Extinguisher Barcode System, where users scan each fire extinguisher using a Mobile Fire Extinguisher Inspection Software App aids with compliance with NFPA and The joint Commission and other Authorities having Jurisdiction(ADJ’s) within Universities, Colleges, Hospitals, Medical Centers, Manufacturing, Oil and Gas and many other sectors.
Easy to Use – Fire Extinguisher Barcode System
IMEC Inspection Software is am easy to use fire extinguisher barcode system which will schedule, manage, track and report on any type of inspection, including Facility, Equipment, People etc. Use Cases include fire extinguisher barcode system, equipment or asset inspection system or facilities inspection software. When used as a fire extinguisher barcode system Inspections are performed via the Mobile app which is available on iOS, Android and Windows devices. The user identifies the inspection point by scanning a barcode, or picking from a list based on location. The Mobile App which is part of the fire extinguisher barcode system will then display the list of custom Forms or Checklists. The fire extinguisher barcode system inspections can be performed offline if no internet connection is available.
The IMEC Mobile Safety App can also be used as a Fire Door Inspection App and with the Web based flexible Forms Manager the solution can be used as a Fire Door Inspection Software Solution also. Fire Door Inspection Software is used is large facilities with large quantities of Fire Doors like Hospitals, Universities and also Cruise Ships.
Not Just A Fire Extinguisher Barcode System but a Complete Fire Life Safety Inspection Software Solution
IMEC Inspection Software can be deployed as a full Fire Life Safety Inspection Software solution that can be used to manage an organization’s full range of fire and life safety inspections. The IMEC Fire Life Safety Inspection Software can manage any type of inspection, use cases include Fire Doors, Fire Pumps, Eyewash Stations, Emergency Lights, Emergency Showers, Grease Traps, AED’s and many more. The IMEC Fire Life Safety Inspection Software can manage any type safety equipment or asset inspection. The user identifies the inspection point by scanning a barcode, or picking from a list based on location. The Mobile App will then display the list of custom Forms or Checklists. The solution can be used within Hospitals as a Hospital Inspection Software solution to manage all hospital inspections and Environment of Care Rounds. Hospital Inspection Software makes Daily, Weekly and Monthly Inspections more efficient and accurate. IMEC’s Hospital Inspection Software allows health care and facility managers to monitor the inspections across their entire organization to aid compliance and increase efficiency.
EH&S Inspection Software
IMEC’s EH&S Inspection Software can be used to manage any type of EHS Inspection and allows manager to record safety observations while performing facility tours which can improve overall workplace safety. This EH&S Inspection Software solution that can create corrective actions as a result of inspection failures for inspections performed using the Safety Inspection Software Mobile App. Corrective actions are allocated to the appropriate persons, with deadlines for resolution which will greatly reduce the time, effort and cost of managing compliance inspections. Implementing an EH&S Inspection software solution, where users using the Safety Inspection Software Mobile App can easily perform inspections in the field aids compliance, reduces risk and standardizes the inspection process within your organization.
Asset Inspection Management Software
IMEC’s Asset Inspection Management Software can be used to manage any type of Asset Inspection. This Asset Inspection Management Software solution can create corrective actions as a result of asset inspection failures for inspections. Corrective actions are allocated to the appropriate persons, with deadlines for resolution which will greatly reduce the time, effort and cost of managing compliance inspections. Implementing an Asset Inspection management software solution, where users using a Mobile App can easily perform inspections in the field aids compliance, reduces risk and standardizes the inspection process within your organization.
Lock Out Tag Out Software Solutions
IMEC’s Lock Out Tag Out Software Solutions allow a LOTO procedure to be defined for each piece of equipment that requires LOTO to be managed within the system. Equipment can be managed from both Mobile and Web App. Isolation points for the each piece of equipment are managed, images associated with both the piece of equipment and isolation points can be annotated to include energy source icon, arrows, sequence etc. Lock Out Tag Out Procedures can be authored using the Mobile App with version control and with an approval workflow. Lock Out Tag Out Procedures are executed using the Mobile App on any Smart Phone or Tablet. Lockout Tagout procedures are initiated by the user identifying the piece of equipment by either scanning QR Code or selecting the piece of equipment from a list. A complete history of completed Lockout Tagout Procedures is recorded. The status for the piece of equipment can be updated after LOTO is complete – Locked / Unlocked. An Audit option on the Mobile App allows a procedure to be reviewed without performing LOTO on the piece of equipment. Corrective Actions can be created for any Non-conformances or changes required recorded during the Procedure Review. Data Analytics within the IMEC Lock Out Tag Out Software Solutions provide machine downtime analysis to aid in operational efficiency and investment decisions.
IMEC Technologies provides Safety Management Software to increase worker safety and aid compliance. IMEC’s Safety Management Software will manage inspections and audits, provides hazard identification, incident reporting, management of corrective and preventative actions from generation to closure. IMEC provides lock out tag out software solutions that will allow users to create lockout tagout procedures using an intuitive Mobile App and Manage Lockout Tagout Procedures, also the Review and Execution of those Lockout Tagout Procedures using the Mobile App. Annual Lockout Tagout Procedures audits are conducted using a Mobile App. The Mobile Inspection App allow users to perform inspections and audits, for example the system can be used as a Fire Extinguisher Barcode Inspection Software system to manage monthly fire extinguisher inspections and general fire safety inspections and also to record safety observations and manage corrective actions, anywhere and anytime. The solution can be used as a fire extinguisher barcode inspection software system or life safety inspection system to aid compliance in Higher Education, Healthcare, Industrial and Commercial Organizations. Benefits from a Fire Extinguisher Barcode System include the elimination of paperwork and reducing the burden of compliance with regulations such as NFPA, The Joint Commission. The Mobile App can also be used as a Fire Door Inspection App and with the flexible Forms Manager the solution can be used as a Fire Door Inspection Software Solution also. Fire Door Inspection Software is used is large facilities with large quantities of Fire Doors like Hospitals, Universities and also Cruise Ships. The Incident Reporting App allows users to easily and quickly report incidents, hazards and near-misses, these are then sent to the appropriate people for action and are managed to closure. Web Apps provide features such as, setup, management, scheduling tools, analysis, reporting and dashboards etc with the ability to report incidents to government bodies such as OSHA and RIDDOR. HazMat T&T is a hazardous waste management software solution designed for Environmental Service Companies and companies who generate a large quantity of hazardous waste. The solution tracks hazardous waste from cradle to grave aiding compliance, providing accurate waste inventory, increasing waste handling efficiency, reducing risk and also helps manage waste costs. HazMat T&T Hazardous Waste Management Software can be deployed in a number of deployment scenarios, from Large Hazardous Waste Generators, tracking their hazardous waste at their site to Environmental Service and Waste Management Companies using it track and manage hazardous waste at transfer and disposal sites. For more information visit our website www.imectechnologies.com