MACHINE SAFETY SURVEYS
Although they are not full-blown risk assessments, as described in ANSI B11-TR3, machine safety surveys provide an overview of safety provisions and operation of individual machines from an experienced and objective viewpoint.
In a typical survey, the operation (task after task) may be observed, along with the condition of the machine and the existing safeguards, and an informal assessment of risk made and documented. Recommendations for risk reduction are provided in a report, along with photographs of the respective machines. We generally allow from 8-15 minutes per machine in the field, plus an equal time for preparation of the report of findings and suggestions.
Our experience and credentials in manufacturing place us in a unique position to not only understand machine operations, but be able to discuss safeguarding options with operators, maintenance personnel, manufacturing and plant engineers and solicit valuable input to aid in the selection of the protective measures that can reduce risk to an acceptable level without a negative impact upon productivity and worker morale.
CASE # 1
A large manufacturer of windows
and doors in
At the end of the survey, the client had what he needed to carry on with the upgrade of his machines – and a host of people who had a better understanding of machine safety and applicable regulations and standards.
“barrel roll” machine poses a
safeguarding challenge at a
CASE # 2
In response to a serious
accident, we were asked to perform
a complete survey of all maintenance shops for a manufacturer of small
A worker wearing gloves sustained a hand injury when the glove caught in the gap between the spinning disc and the workrest
When a large manufacturer in Massachusetts ordered a 5000 Ton hydraulic press from Germany, they called ESA to assist in reviewing safeguarding for compliance to US standards – and reducing the excessive noise from the massive hydraulic pumps and reservoir at the top of the three and a half story machine.
We spent several days in
CASE # 4
A trip to
Again, we started with meetings to define the task, and then proceeded to survey hundreds of machines in every possible scenario, from woodworking to clay molding to metal stamping to small assembly.
Our full report was over 250 pages long with incorporated photos and recommendations.
CASE # 5
Working on a grant with the
Rochester Institute of
Technology, we surveyed this metal stamping facility in
CASE # 6
A near miss at an automotive
In this instance the ESA team not only reviewed the physical aspects of machine safety, but analyzed machine control schematics and systems as well, since the incident was allegedly caused by a control malfunction.
Our capabilities in this area
have been tapped several times
in the past few years at plants from
press at an
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