the importance of maintenance in your safety...

The Importance of

Maintenance in Your

Safety Program

Region I VPPPA Show

June 2013

What’s Wrong Here?

Any Issues?

Search “Maintenance”

Search “Maintenance” – May 5th

287,000

So…..

So how important, or how

much are we relying on our

Maintenance Department

for compliance?

So…..

#11 On The List

OSHA Web Site

Top Cited Items for “Manufacturing”

Mechanical Power Transmission Apparatus

1910.219(p)

Care of equipment -

1910.219(p)(1)

General. All power-transmission equipment shall be inspected at intervals not exceeding 60 days and be kept in good working condition at all times.

1910.219(p)(2)

Shafting.

1910.219(p)(2)(i)

Shafting shall be kept in alignment, free from rust and excess oil or grease.

Mechanical Power Transmission Apparatus

1910.219(p)(2)(ii)

Where explosives, explosive dusts, flammable vapors or flammable liquids exist, the hazard of static sparks from shafting shall be carefully considered.

1910.219(p)(3)

Bearings. Bearings shall be kept in alignment and properly adjusted.

1910.219(p)(4)

Hangers. Hangers shall be inspected to make certain that all supporting bolts and screws are tight and that supports of hanger boxes are adjusted properly.

1910.219(p)(5)

Pulleys.

1910.219(p)(5)(i)

Pulleys shall be kept in proper alignment to prevent belts from running off.

Contractors

• Contractors are a part of daily life

• Many times performing high risk maintenance

functions

• How do you manage this?

– Ensure compliance

– Work together on a safer workplace

So…..

Contractor Safety

18

SAFETY CULTURE & OSHA VPP

Contractor Safety

This presentation contains no technical data subject to the EAR or ITAR

Contractors

• A Robust Contractor

Management Program

– Clear expectations

– Written rules

– Pre Job Start analysis

– Test to prove safety

competence for varying

levels of work performed

(based on risk)

20

SAFETY CULTURE & OSHA VPP

Contractor Safety

This presentation contains no technical data subject to the EAR or ITAR

CARDINAL RULES

The Cardinal Rules represent five of the

critical safe work practices that must be

followed to help us continue toward our goal

of creating the safest work environment

possible for employees.

You can help by:

Being aware of the rules

Choosing to act in a safe manner by

following the rules

Making a conscious effort to identify

potential violations

Be alert and stay safe!

January 2011 This presentation contains no technical data subject to the EAR or ITAR

Combustible Dust

Dust Collectors

Dust Collector Neglect

To inspect, 2 maintenance

personnel needed to

use a ladder, pull up and

look into this filter unit…

Target filter area…

..made an inspection window…

..added labeling…

Filter pressure drop ….

To lubricate these

fittings we have to:

Lock out the

machine,

climb the ladder and

lubricate…..

During TPM Focused Improvement Event,

Changed and relocated these fittings

Lower to access ...

Grease

fittings are

now only 3

feet from floor

level!

They can be

greased

during normal

operation!

What’s the condition

of the chain here??

300 chain drives & conveyors

$15K chains & sprockets annually

Operations 24/7

Dry/loose conditions

Sprockets loose….

Can we monitor this

on a regular basis….

Operator can inspect and

lubricate without

shutting down, locking out…

Increased equipment up-time

Lowered risks

$5K annually

PPE usually

needed when

exposed to

voltage

Infrared Viewing Ports

Typical Medium Voltage Distribution System

Guidance Documents

Maintenance in the Standard

The word

“maintenance” is

referred 66 times

in the body of this

document

Energy Control - LOTO

When is Energy Control Needed?

• When you are servicing or repairing

machinery AND the unexpected

energization or release of stored energy

could cause injury.

Energy Control Program

Problems

Example of a Visual LOTO Form

What Maintenance

Functions are required

for a Power Press Safety

Program?

Maintenance & Training

1910.217(e)(3)

Training of maintenance personnel. It shall be the responsibility of the employer to insure the original and continuing competence of personnel caring for, inspecting, and maintaining power presses.

1910.217(e)(1)

Inspection and maintenance records.

1910.217(e)(1)(i)

It shall be the responsibility of the employer to establish and follow a program of periodic and regular inspections of his power presses to ensure that all their parts, auxiliary equipment, and safeguards are in a safe operating condition and adjustment. The employer shall maintain a certification record of inspections which includes the date of inspection, the signature of the person

who performed the inspection and the serial number, or other identifier, of the power press that was inspected.

Respiratory Protection

Respiratory Protection

• 1910.134(h) Maintenance and care of respirators. This paragraph requires the employer to provide for the cleaning and disinfecting, storage, inspection, and repair of respirators used by employees.

• 1910.134(h)(1) Cleaning and disinfecting. The employer shall provide each respirator user with a respirator that is clean, sanitary, and in good working order. The employer shall ensure that respirators are cleaned and disinfected using the procedures in Appendix B-2 of this section, or procedures recommended by the respirator manufacturer, provided that such procedures are of equivalent effectiveness. The respirators shall be cleaned and disinfected at the following intervals:

• 1910.134(h)(1)(i) Respirators issued for the exclusive use of an employee shall be cleaned and disinfected as often as necessary to be maintained in a sanitary condition;

• 1910.134(h)(1)(ii) Respirators issued to more than one employee shall be cleaned and disinfected before being worn by different individuals;

• 1910.134(h)(1)(iii) Respirators maintained for emergency use shall be cleaned and disinfected after each use; and

• 1910.134(h)(1)(iv) Respirators used in fit testing and training shall be cleaned and disinfected after each use.

What’s Next?

• Teambuilding

– Focused Events – Total Productive

Maintenance (TPM)

• Integration of Lean and Safety

• Audits

• Awareness Programs (RIDII, etc.)

Thank You