MPSA Mission Statement

The Machinery and Process Safety Assessment Group is comprised of safety professionals experienced in manufacturing and their related safety fields.

Our mission is...

To reduce our customers’ manufacturing-related accidents, by providing assistance with machinery and process hazard identification,

classification and reduction.

To bring our customers current guidelines and principles, as outlined by the Occupational Safety and Health Administration, as well as other industry

recognized standards.

To provide an opportunity for all employees to grow and prosper as team members, as well as individuals.

To prosper as a company, by providing education and solutions in machine and machine tool safeguarding.

MPSA Services Provided

Risk Assessment for Machines and Machine Tools

A detailed risk assessment will be performed, identifying points of hazard, as defined in OSHA 29CFR 1910, Subpart O. OSHA also recognizes other standards, such as ANSI, and incorporates these guidelines, adopting them by law.

We will make industry accepted recommendations for mechanical hazards, as well as identify non-mechanical hazards that affect the Control Reliability of the machine.

The Control Reliability non-mechanical hazards pertain to the electrical, pneumatic and hydraulic components and circuits, and their operations, related to the safety of the equipment.

We will have the ability to not only identify these hazards, but also develop a potential solution to properly safeguard the hazards.

MPSA Services Provided

Training and Education for Machine Safeguarding

A full training program will be developed, in order to educate people in:

• OSHA Regulations

• Risk Assessment

• Types of Guarding

• Safety Components and Safety Component Construction

• Design Considerations

• Implementation

• Validation

Why use MPSA?

According to the Job Hazard Analysis Handbook from the Occupational Safety and Health Administration,

“If your employees are involved in many different or complex processes, you need professional help conducting your job hazard analyses.”

That’s where we come in!

Why use MPSA?

To achieve your goals:

• Reduce Lost Work Day Injury (LWDI) rate (OSHA has industry averages for each SIC code, and if you are over

the average, you are a target for an inspection!)

• Reduction of Insurance-related costs related to machine and process related injuries.

Why use MPSA?

Some hazards are easy to identify,

like this...

Why use MPSA?

Or this...

Why use MPSA?

Or this...

Why use MPSA?

Or this...

What About Hidden Hazards?

The hidden hazards pertain to the control system.The control system refers to the electrical, electronic,

pneumatic and hydraulic systems.

ANSI B11.19-1990(R1997)5.5.1 Control Reliability“When required by the performance requirements of the safeguarding, the device, system or interface shall be designed, constructed, and installed such that a single component failure within the device, interface or system shall not prevent normal stopping action from taking place but shall prevent a successive machine cycle. This requirement does not apply to those components whose function does not affect the safe operation of the machine tool.” E5.5.1 Interpretation“Control reliability of electrical, electronic, or pneumatic systems frequently consists of multiple, independent parallel or series circuitry or components so arranged that any single failure would not significantly affect the stopping performance of the system or machine tool. If a failure of a component has occurred, this arrangement either sends a stop command to the machine tool or prevents a successive cycle from being initiated.”

MPSA Finds the Hidden Hazards

It’s easy to see how some hazards can be identified. But what do you do about the ones you don’t know about?

MPSA can identify and record these Machinery and Control Reliability related hazards.

Our assessments are not only thorough and comply with federal and international guidelines, but they are communicated to you every step of the way!

You, our customer, specify the detail you require. The following slides will illustrate the three levels of detail which can be provided to you.

MPSA’s 3-Tier Concept

TIER ONE

Identify Hazard

TIER THREE

Recommend Product with Part Number

TIER TWO

Recommend Solution

Reference #:Department:

Area/Line:Equipment ID#:Desc. of Oper.:

1,2Packaging

Line #4P3401MOperator feeds film into rollers to be printed

Sample

Report

Probability of Occurrence:

Customer Received Information:

Severity of Harm:Customer Received

Information:

Risk Estimation:

Likely

Operator interfaces with hazard point 5-6 times per shift

Determination of injury can be debilitating, but can return to work

High

Serious

Sample

Report

Full Machine View

Reference 1Tier 1: FindingsIngoing nip point on rollersTier 2: SolutionLight curtains can be used without causing any impedance for normal operationTier 3: SpecificationsPart # STI MS47-12-300-LCM1-10X-10R-RM1

Control Reliability, ElectricalTier 1: FindingsControl system is not control reliableTier 2: SolutionInstall positive force guided devices having redundancy and monitoringTier 3: SpecificationsPart # STI FGR31-24S

Sample

Report

Full Machine View

Control Reliability, PneumaticTier 1: FindingsEmergency Dump Valve is not control reliableTier 2: SolutionInstall Safety Rated Dump ValveTier 3: SpecificationsPart # Ross 3573D3191

Control Reliability, HydraulicTier 1: FindingsN/A

MPSA’s 3-Tier Concept

Excel OverviewGeneral assessment, recommendations and part numbers

What is the “BLACK BOX”?The “Block Box” is a system solution not just a component

or a single guard. A system consists of the mechanicalguarding as well as the electrical, pneumatic and

hydraulic control systems. Our concept is to fabricate asmuch as possible offsite in the shop and integrate oursystem at the time of install. We can create the entire

safety system into a stand alone enclosure and tie into

the points on the machine where required.

Black Box Components

Limited Space in Enclosure

Black Box Next To Enclosure

Existing Guarding Inadequate

New Guarding System Installed

Indicator Light for Open Doors

OSHA FactsAccording to the Field Inspection Reference Manual, CPL 2.103,

issued by the Occupational Safety and Health Administration:

“(5) The rate of penalty reduction for size of business, employer's good faith and employer's history of previous violations shall be calculated on the basis of the criteria described in the following paragraphs:

(a) Size. A maximum penalty reduction of 60 percent is permitted for small businesses. "Size of business" shall be measured on the basis of the maximum number of employees of an employer at all workplaces at any one time during the previous 12 months.

1 The rates of reduction to be applied are as follows:

Employees Percent reduction

1-25 60 26-100 40 101-250 20 251 or more None

OSHA FactsAccording to the Field Inspection Reference Manual, CPL 2.103,

issued by the Occupational Safety and Health Administration:

g. Gravity-Based Penalty. The gravity-based penalty (GBP) is an unadjusted penalty and is calculated in accordance with the following procedures:

(1) The GBP for each violation shall be determined based on an appropriate and balanced professional judgment combining the severity assessment and the final probability assessment.

(2) For serious violations, the GBP shall be assigned on the basis of the following scale:

Severity Probability GBP Gravity

High Greater $5,000 high ($5,000+) Medium Greater $3,500----

Low Greater $2,500 |-- moderateHigh Lesser $2,500 | Medium Lesser $2,000---- Low Lesser $1,500 low

NOTE: The gravity of a violation is defined by the GBP.

o A high gravity violation is one with a GBP of $5,000 or greater. o A moderate gravity violation is one with GBP of $2,000 to $3,500. o A low gravity violation is one with a GBP of $1,500.

Off to a Good StartAccording to the Job Hazard Analysis Handbook from the

Occupational Safety and Health Administration,

“It is important for you and your employees to be involved in the process of identifying and correcting hazards, because you are on the worksite every day and most likely to encounter the hazards.”

“New circumstances and a recombination of existing circumstances may cause old hazards to reappear and new hazards to appear.”

“You must be ready and able to implement whatever hazard elimination or control measures are recommended.”

Are you ready to take it to the next level?