Upcoming 2025 Training Dates:

• February 11-12, 2025 (current)
• May 13-14, 2025
• August 12-13, 2025
• September 9-10, 2025
• October 21-22, 2025
• December 9-10, 2025

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

The topics are as follows:

Session 1 – (12:30 PM to 4:30 PM EST) – February 11th

• 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 – (12:30 PM to 4:30 PM EST) – February 12th

• 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

2025 Technical Breakout Sessions

• February 13, 2025 (Current)
• May 15, 2025
• August 14, 2025
• September 11, 2025
• October 23, 2025
• December 11, 2025

Technical Break-Out 1  – (12:30 PM to 1:30 PM EST) – February 13th

• 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.

Technical Break-Out 2  – (1:30 PM to 2:30 PM EST) – February 13^th

• 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.

Technical Break-Out 3  – (2:30 PM to 3:30 PM EST) – February 13th

• 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.

Technical Break-Out 4  – (3:30 PM to 4:30 PM EST) – February 13^th

• 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.

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Note:  Example safety devices from various manufacturers are displayed during the presentation.  As training progresses, these product examples are shown to the class for students to see via Microsoft Teams or other video conferencing platform upon request.

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.

Training Notes:

1. Training is purchased per seat (per person).  Training may not be shared with other persons unless it has been specifically arranged and agreed upon in writing before training begins. A pdf file of the training materials will be supplied just prior to the course.
2. The training may be recorded.  A copy of the recording is not typically provided unless it has been specifically arranged and agreed upon in writing before training begins.   Any recordings are subject to technical limitations, settings, and conditions of the meeting platform (Teams, etc.) in place at the time of training.

Instructor Bio

Ken Hackworth, PE, FS Eng. (TÜV Rheinland)

Ken Hackworth, PE has more than 30 years of experience in industrial controls and functional safety systems and is a licensed Professional Engineer (PE) and a certified Functional Safety Engineer.  Ken received his Bachelor of Science in Electrical Engineering from The Ohio State University, is a subcommittee member of ANSI B11 safety standards and a member of the American Society of Safety Professionals.

Ken is experienced and certified in U.S. and international safety standards, including OSHA, ANSI, NFPA, RIA, and ISO/EN standards and specializes in machine safety engineering and compliance consulting.  As a trainer for OSHA, Ohio BWC and several multi-national industrial clients, Ken enjoys training safety professionals, technical staff and business leaders in the latest technology and safety standards for industrial machinery.