We offer 1- or 2-day classes covering advanced machine safeguarding, safety standards, and risk assessment topics.

See our On-Site training agenda below for our Instructor-led Training.  Each class syllabus can be customized for your particular application and safety needs.

Instructor-led Training is typically performed at your site.  Click here to learn more about Instructor-led Training, including pricing and schedule availability.

For additional training resources please click here

Short Description

In this training, safety professionals, technical personnel, engineers and managers will develop and understanding of the latest OSHA, ANSI, NFPA, RIA (industrial and collaborative robots) and ISO/EN requirements for industrial machine safety and risk assessment.

Learning Objectives

Upon completion of this training, you will be able to:

• Identify machine related workplace hazards
• Understand applicable U.S. machine safeguarding requirements
• Inspect and recommend compliant machine safeguarding
• Complete an OSHA/ANSI compliant risk assessment
• Understand advanced concepts, such as:
  • Control reliability and functional safety
  • Alternatives to Lock-out/Tag-out (LOTO – Hazardous Energy Controls)
  • Industrial and collaborative robots
  • Risk assessment and risk reduction strategies
  • Liability and legal concerns

Session 1:

• • Why improve machine safety?
    • Injury prevention, compliance, the law
  • OSHA Basics of machine guarding (abbreviated)
  • Hierarchy of controls w/ examples
  • Hazard recognition:  Basics, Intermediate, Advanced (embedded in training)
  • Functional Safety
    • Introduction to Control Reliability, Category 3 circuits, and guard interlocks
  • OSHA 1910.147 – OSHA requirements for Alternative Protective Methods and the Minor Servicing Exception to LOTO / ANSI Z244.1
  • Safety Distances

Session 2:

• ANSI B11.19 – Modern machine safeguarding requirements
• NFPA 79 – Stopping Functions / Emergency Stop Requirements
• Comparison of US and ISO/EU machine safety standards (abbreviated)
  • CE marking
• Introduction to Industrial and Collaborative Robot Safety: OSHA / RIA 15.06 / RIA 15.606
• ANSI B11.0 – Risk Assessment
  • Quantifying the risk
• How to perform a Risk Assessment
  • Why do a risk assessment?
  • Risk Assessment System
  • Risk Factors: Severity, Exposure, Probability
  • Risk Assessment spreadsheet tool overview
• Conclusion and Wrap-up

Session 3:

Hands-On Risk Assessment (RA) Workshop

The purpose of the Team Based Risk Assessment (RA) is to identify the remediation (safeguarding) required to reduce the risk within tolerable levels and comply with all applicable safety regulations. In a RA, a multi-disciplined team identifies tasks and risks of the machine. The risk is scored (with and without safeguarding) and a safeguarding plan is developed. This RA document is then accepted by the team and forms the basis of the remediation (safeguarding) plan. For complex machinery, a team-based risk assessment is an essential process that is required to develop practical, detailed risk reduction measures.

The following items are included:

• Risk Assessment Workshop – select a machine in client’s facility and perform a risk assessment, to the extent feasible within the time allowed.
• MSS to guide discussion and update the Risk Assessment Spreadsheet during this conference. Client to include in the meeting, as a minimum, the following authorized personnel: Operator, Maintenance, Engineering, and EHS.
• Guidance of the Risk Assessment workgroup for a machine/process as needed to:
  • Identify hazards
  • Review drawings and technical details
  • Score in terms of severity, probability, and frequency
  • Guidance in use of spreadsheet tool
  • Checking, correcting, approval
  • Facilitate team discussions and team engagement

Note:  Example safety devices from various manufacturers are displayed on a table in the classroom.  As training progresses, these product examples are passed around the class for students to see/handle.

As time permits, our consultants include practical, real examples and illustrations from more than 30 years’ experience inspecting, consulting, and conducting accident investigations in more than 500 plants across the US, Canada, Mexico, and Japan. Machine Safety Specialists are machine safety trainers for OSHA, Ohio Bureau of Workers Compensation (BWC), and the American Society of Safety Engineers.

Deliverables

• A softcopy training manual is provided for each student (hardcopies available for purchase). This training manual includes the training presentation.
• Optional: One (1) MSS Universal Safety Scale (“Gotcha-Stick”)
• Risk Assessment document (spreadsheet) in compliance with ANSI/RIA TR 15.306 (Session 3 only)

Client to Provide

• Classroom facility with projector or large monitor.
• Lunch and drinks for students and instructor(s)

A description of each technical breakout session is shown below.  The above machine safety and risk assessment training is a pre-requisite for each technical break-out session listed below.

Industrial robot safety:  Includes an overview of industrial robot safety requirements in accordance with ANSI/RIA 15.06 (ISO 10218) and ANSI/RIA TR 15.306.  This presentation goes into more detail than the general safety training course.

Collaborative robot safety:  Includes an overview of collaborative robot safety requirements in accordance with RIA TR R15.606 (ISO/TS 15066).  This presentation goes into more detail than the general safety training course.

Stop-time measurement classroom training:  Includes classroom training covering ANSI B11.19 requirements for stop time measurement.  Includes example case study (presentation).  Includes live demonstration of a stop-time meter in the classroom.

Stop-time measurement hands-on exercise:  Includes stop time measurements on one (1) machine in your facility which interactive participation from students.   For machines with “wearable” braking mechanisms (such as friction brakes), a stop time measurement should be performed on an annual basis in order to ensure that the machine’s stop time has not changed.

Safety Requirements for Bypassing (Suspending) Guards: This session provides advanced training showing U.S. and ISO requirements for operating powered industrial machinery with exposure to hazards with guards removed or bypassed.  Includes detailed instruction and discussion on required engineering controls and administrative measures.

Advanced functional safety and control reliability:   Overview of ANSI B11.26 for technical personnel including engineers, technicians, and Sr. maintenance personnel.  Includes recommendations and requirements for functional safety systems including fluid power safety systems (hydraulics and pneumatics).  Typical safety system designs are reviewed and discussed including schematic diagrams for safety control systems, hydraulic systems and pneumatic (air) systems.

Roller and Conveyor Guarding: This session covers OSHA and ANSI safeguarding recommendations for conveyors and machines with roller hazards. Includes a summary of requirements from OSHA, ANSI and ASME safety standards as they pertain to safeguarding of rotational hazards, conveyors and in running nip hazards. Includes discussion on best practices for safeguarding conveyors and rollers.

Safe Entry Requirements for Manufacturing Cells:  Complex manufacturing systems (such as industrial robot cells) expose employees to high-risk machinery hazards during cell entry if risk reduction methods are inadequate. This technical training session covers a four (4) step safety design process needed to properly apply engineering controls to manufacturing systems with perimeter guarding. This class presents up-to-date guarding and functional safety requirements in consideration of hazardous energy control requirements (LOTO) and OSHA’s minor servicing exception.

Custom Training Session: This custom session is planned for up to two (2) hours (includes up to 30 minutes of Q/A and discussion). Includes preparation of training material and safety engineering review and approval of content prior to presentation.